Here's a method that I'm going to try to clean the rust off my exhaust manifolds - electrolytic rust removal. Here's the FAQ location
http://www.bhi.co.uk/hints/rust.htm
Basically, you use electrolysis, dip the manifold in a solution with washing soda/water, use a stainless steel electrode and a battery charger and hook the mess up. Leave it overnight or longer and supposedly the rust will rub off. They suggest a plastic tub or bucket but I thought that an old stainless sink would do better as it could be used for the positive anode. The part to be cleaned is attached to the negative of the battery charger.