Am I expecting too much from my zinc plating process? I recently bought a 1.5 gallon zinc kit and constant current power supply. I am restoring a ’65 MG Midget and using the process to refurbish under hood fasteners and hardware. I have two goals, the most important is rust prevention, and secondly, appearance. I am using clear zinc plating to match the original finish, no chromates.

I am still learning and trying to follow instructions. My process for rusted nuts and bolts is this:
1. Remove rust by electrolysis. 12-volt battery charger, lye and water, angle iron electrodes.
2. Clean in lacquer thinner.
3. Dip in 33% sulfuric acid to remove residual rust
4. Polish with wire wheel. Repeat acid dip and wire bush if needed.
5. Soak in SP degreaser.
6. Spray with distilled water.
7. Plate at .14 amp per square inch for 20-30 minutes. Brightener added.

The parts appear to plate nicely, about .001 thick after 30 minutes. When I compare the parts to new zinc plated bolts they are dull and appear to have a haze on them. However, they do shine up nicely by lightly hitting them with the wire wheel but that leaves them with fine scratches. I’m sure the wire brushing is also removing some of the zinc coating which no doubt shortens the life of the protective plating. They polish up like chrome with a buffing wheel and compound and look as good or better than new bolts except for the pits left from the corrosion.

Is it possible to have them come out of the plating tank looking like store bought bolts or is what I’m getting as good as can be expected? I had the thought that the commercial platters may be getting the same thing that I am out of the tank and then using vibratory tumblers to polish the parts. I would like to pull the parts from the tank nice and shinny but is that asking for too much from zinc plating?