DO IT: Projects, Plans, and How-tos

Anodizing is a process that builds up a very thin but strong protective layer on the surface of a non-ferrous metal. It is achieved using chemical/electrical oxidization, and is most commonly done on aluminum , but occasionally also seen on titanium, silver and other metals. If you’ve ever seen one of those blue or red Maglite flashlights (and I’m sure you have), you’ve seen anodized aluminum. The color comes from dyes that are used after the anodizing process to give it color before sealing the surface layer tightly.

Although aluminum anodizing is often done for large-scale commercial uses, the process is reproducible for smaller home-brew projects using easy to find chemicals and containers (like plastic coolers). The best set of DIY instructions around come from Ron Newman – he has a detailed breakdown of each step, and even sells the solutions and kits to get you started. Here’s a simple overview:

• Soak aluminum part in cleaning solution
• Etch part in caustic lye solution
• Desmut (done if etched or for certain aluminum alloys)
• Connect part to positive electrode of power source, with cathode (negative electrode) submersed in anodizing solution. Submerse for one hour.
• Dye
• Seal part using nickel acetate sealer

Of all the steps, the most involved is setting up the power supply to charge the solution and cause the anodizing process to occur. A battery charger is a simple tool that can work here, although Newman’s writeup says to use a somewhat pricey rectifier to help control the current to the proper level to get decent results. Other anodizing pages such as from Steve Mass and Bryan Pryor suggest that the battery charger can be difficult to monitor and control – they prefer using a dedicated DC power supply instead.

Caswell plating sells supplies for anodizing – check with them for materials.

On a larger, industrial scale, full factories are used to anodize oversized pieces of metal for building purposes. The general process is the same though.

Now, lets say you need to remove the anodizing for some reason or other (perhaps you don’t want your paintball gun to look like a pink and blue easter egg anymore). The system is pretty straightforward:

You can strip off the existing anodized layer from any anodized part by placing the part in a caustic solution for an hour or so.  Just mix a few tablespoons of lye and water in a plastic container.  Wear eye protection and rubber gloves for this procedure!!  Place the part in the solution and monitor its progress.

The Lye will dissolve the old anodized layer, about .001″ thick.  It takes a while for it to start breaking through the layer.  It’s a little slow at first.  The first ten minutes or so not much action will be seen.  Bubbles and smut will rise up as an indicator of its progress.

Or, you can use a parts washer like this video shows:

And, as mentioned above, you can use this technique on other metal types. Here’s a demonstration of anodizing a bar of silver:

Finally, one more page with a full rundown on the anodizing process: DIY aluminum anodizing

Now, go anodize some stuff! Car parts, bike parts, water bottles, pizza peels. Let your imagination run wild, just like the wild colors you can use.

Koshari is a traditional dish from Egypt, one that tastes so good I can’t stop eating until nothing is left. The dish has many parts, all of which are pretty simple but combine together for complete deliciousness: Rice/lentil (referred to as koshari), spicy tomato sauce, macaroni, garbanzo beans and fried onion.

Here is the recipe to make the best tasting koshari I’ve had so far. I’ve based the approximate measurements off of the video I took of Magda and Sandra demonstrating how to cook the dish (very special thanks to both of them for taking the time to let me film this and feeding me).

Ingredients:
Koshari:
1 large yellow onion, chopped
1/2 cup corn oil
1lb lentil beans
2 cups basmati rice
4 cups water
1 tablespoon plain tomato sauce
1 glove of garlic, crushed

Sauce:
(2) 16oz cans  of tomato sauce (video says 6oz – was meant to say 16oz)
1 tablespoon corn oil
5 cloves of garlic, crushed
1 teaspoon salt
1 teaspoon pepper
1/2 teaspoon cinammon
2 tablespoon white vinegar
1 green chili pepper or 1/2 teaspoon red pepper flakes (optional)

Pasta:
1lb macaroni, small size (elbows)
1 teaspoon salt
1 teaspoon pepper

Garbanzos (topping):
1 can garbanzos, drained and rinsed
1 teaspoon salt
1 teaspoon pepper
1 teaspoon cumin
1 teaspoon garlic pepper
1 tablespoon lemon juice

Instructions:
Koshari:
– Begin by soaking the lentils and rice in water for about 30 minutes (separately). You don’t want the lentils to get too soft, so don’t over-soak them.
– Chop the onion coarsely – about 1/2″ squares. Put in large stock pot, add corn oil so the onion is covered. For one onion, this was about 1/2 cup.
– Heat on medium-high, stirring regularly. Cook until darkish brown, about 15-20 minutes. Watch closely as the onion goes from dark brown to burnt very quickly.
– When finished, remove onion from stock pot with slotted or perforated spoon. Place onion on paper towel to drain. Keep oil in pot.
– Add one clove crushed garlic to the oil.
– Stir in four cups of water and one tablespoon of tomato sauce.
– Add lentils when the water begins to boil, cover and cook until lentils start to soften (about 20 minutes).
– Once lentils soften a touch, stir in rice, cover, and continue to heat.
– Finished once water is soaked up and the lentil/rice mixture is soft and fluffy.

Sauce:
– Crush five cloves of garlic, put into saucepan with a tablespoon of corn oil.
– Heat on stove, medium-high.
– Add 1 to two tablespoons of white vinegar and two 16oz cans of plain tomato sauce.
– Thin sauce with 1/4 to 1/2 cup of water.
– Pinch of salt, pepper and cinnamon to the sauce.
– Chop a green pepper and add to the sauce, or use red chili flakes
– Cover, bring to a boil, then reduce heat and let simmer for 20 minutes

Pasta:
– Boil water in large pain
– Add one pound small macaroni shape. Elbows work well.
– Cook slightly longer than the directions call for – you want the pasta to be soft.

Garbanzos:
– Drain and rinse a can of garbanzo beans (chickpeas)
– Mix in salt, pepper, cumin, garlic powder
– Sprinkle with lemon juice

Prepare by making a bed of the rice and lentils, add macaroni on top, coat with sauce (the sauce is my favorite part – that vinegar/cinnamon addition makes it so tangy-good), top with garbanzos and fried onions. Serve with a nice cucumber and tomato side salad.

Serves six. Or one, if I’m there.