Just joined your forum to share my experiences of Phosphoric Acid
I bought 84% Phosphoric Acid and used it mixed approx 50/50 with distilled water to give 40%. I tried it around 30% and it was slower. I tried it around 60% and it was also slower (too viscous?). Someone I met on another forum claims chemical rust treatment as his area of expertise and suggested to add a small amount of surfactant ( eg <1% household detergent), and also pointed out that many of the commercially available products also blend in citric acid.
My technique was to remove the vast majority of rust with a combination of abrasives, scourers, and many many 5" whire wheels on my grinder and then dust down the whole area before applying my acid treatment with a foam 4" paint roller.
The treatment leaves a thin dark layer of dried-on acid and rust residue which reacts with water to produce a much thicker layer of a chalky powdery substance. Paint can be applied to the dark residue but does not adhere to the powdery substance at all, so the smallest chip in this paintwork becomes a big lumpy chalky blister in weeks.
The solution I found is to give the treated metal a quick tickle with a wire wheel on the grinder, doesn't need much pressure to get through the residue and down to the bottom layer of black. This protective layer is attached to the metal so well that you'll stuggle to move it with a wire wheel on a grinder, but abrasives will go straight through it!
In response to bobbybass: They're not allowed to send it through the post above a certain strength, which is why many commercial products are 25% - 30% when 40% works better. My 5l of 84% arrived by courier. You can buy the same chemical by the litre over the counter of your local "growshop" where it's used for adjusting the acidity of the feed in hydroponic systems but for the same reasons it's still only 30% (sold as "ph down for bloom", if anyone's interested)