Cleaning Cast Iron Popover Pans: A Step-By-Step Guide

Cast iron cookware is highly prized by cooks and collectors alike. However, cast iron does require some special care when it comes to cleaning and maintenance. This is especially true for cast iron popover pans, which can be tricky to clean due to their shape. In this article, we will explore the best ways to clean and maintain your cast iron popover pan, so that it stays in top condition for years to come.

Use electrolysis to clean off rust and crud

Electrolysis is a highly effective method for removing rust and crud from cast iron. The process involves passing an electrical charge through an electrolyte solution, causing a chemical change that damages a "sacrificial anode" while repairing the cast iron item. This technique is particularly useful for collectors and restorers of vintage cast iron cookware, as it does not cause scarring or pitting on the pan.

Gather the necessary materials:

• A large plastic container, such as a 20-gallon garbage can or a plastic storage container, to use as an electrolysis tank.
• Sacrificial anodes made of regular steel or iron. These can be items like old rebar, plain steel sheeting, or used lawnmower blades.
• A car battery charger with a manual mode, preferably one with adjustable voltage and current settings.
• Washing soda (sodium carbonate), which will be used to create the electrolyte solution. Do not use baking soda, as it is a different chemical compound.
• A piece of wood, such as a 2x4 lumber, or a non-conductive material like PVC pipe, to hang the popover pan inside the tank.
• Water to submerge the pan.
• Steel wire or coat hanger wire to hang the pan.
• Rubber gloves for handling the pan during and after the process.

Set up the electrolysis tank:

• Drill holes at the top of the container and use zip ties to mount the sacrificial anodes securely. Connect the anodes together using wire.
• Add washing soda to the tank at a rate of 1/2 cup of washing soda for every 10 gallons of water. Stir until the washing soda is completely dissolved.
• Place the popover pan inside the tank, ensuring it does not touch the sides or the anodes. You can use the wood or PVC pipe to hang the pan so that it is suspended in the water.

Connect the battery charger:

• Attach the negative (black) lead of the battery charger to the popover pan. It is crucial to get the polarity right; otherwise, you may cause the pan to rust further.
• Connect the positive (red) lead to the sacrificial anodes.

Perform the electrolysis:

• Turn on the battery charger and set the voltage and current to the lowest setting. You may need to adjust the settings depending on the amount of rust and the size of your setup.
• The cast iron pan should start to bubble in the water. Check on the pan periodically by turning off the power supply and removing it from the tank.
• The electrolysis process is complete when all the reddish-brown rust is gone or has turned into a soft, black residue that can be easily wiped or scrubbed off. This can take anywhere from an hour to a day or more, depending on various factors.

Final cleanup:

• Remove the pan from the tank and place it in a sink. Use a steel wool pad or a steel wire brush to clean off any remaining residue. If necessary, put the pan back in the tank for further treatment.
• Give the pan a final scrub with mild dish detergent and rinse it thoroughly with cold water. Dry the pan completely in a warm oven set between 200 and 350 degrees Fahrenheit.

Note: Always exercise caution when working with electricity and chemicals. Ensure proper ventilation during the electrolysis process as it produces small amounts of flammable hydrogen gas.

Use a lye bath to clean off crud and old seasoning

Lye is a caustic substance, meaning it has a very high pH level. It is highly alkaline and can be dangerous if mishandled. When using lye, it is important to wear protective clothing, including eye protection, and rubber gloves. It should be noted that lye should never be added to water – always add water to lye. This is because the reaction of lye with water is exothermic, meaning it can cause a violent, hot reaction.

To clean a cast-iron pan with lye, you will need a large, sturdy plastic container with a secure lid to keep out children and pets. The container should be able to hold five gallons of water. You will also need a product that is 100% lye (sodium hydroxide) such as Rooto Household Drain Opener or Roebic Crystal Drain Opener. The ratio is one pound of lye crystals to five gallons of water.

To begin, put on protective clothing, including gloves and eye protection. Always add the lye to the water, and never the other way around. This will create a thermal reaction, which can be dangerous. Add one pound of lye crystals to five gallons of water, in your plastic container. Then, suspend your cast-iron popover pan in the lye bath, using steel coat hangers. Allow the pan to soak for several days. The length of time will depend on how thick the build-up of crud is on the pan. Rinse the pan well after removing it from the lye bath.

It is important to note that lye will not remove rust from cast iron. To remove rust, you will need to soak the pan in a solution of 50% white vinegar and 50% water for several hours. Be careful not to leave the pan in the vinegar solution for too long, as vinegar is an acid that can eat away at the metal.

After removing the crud and rust, the pan will need to be seasoned to prevent further rusting and to create a non-stick surface.

Dry the pan on the stove to prevent rust

Drying your cast iron popover pan on the stove is an important step in the cleaning process. Cast iron is prone to rusting, so it's crucial to ensure that all the water is completely gone after rinsing or boiling water in the pan. To do this, simply place the pan back on the stove and turn the burner to high. Wait for the water to boil off—this will leave the pan parched and rust-resistant.

After boiling off the water, it's essential to dry the pan thoroughly with a lint-free cloth or paper towel. Don't be alarmed if you notice some black residue on your towel—this is just the seasoning coming off, and it's perfectly normal.

Once the pan is completely dry, it's time to re-season it. This process involves bonding oil to the iron to create a rust-resistant, non-stick surface. Start by heating the pan on the stove until it's very hot. Then, using a paper towel, rub a thin layer of oil all over the pan. Canola oil, flaxseed oil, or avocado oil are good choices for this step. Make sure to wipe off any excess oil with a clean paper towel, as you don't want a thick layer of oil on your pan, which would result in a sticky mess. Allow the pan to cool before storing it.

By following these steps, you'll be able to effectively dry your cast iron popover pan on the stove and prevent rust from forming.

Season the pan with avocado oil

Seasoning a cast iron popover pan with avocado oil is a great way to protect the pan from rust and corrosion while also creating a non-stick surface. Avocado oil is a good choice for seasoning cast iron because it has a high smoke point of 520°F (271°C) and a neutral flavour. Here is a step-by-step guide to seasoning a cast-iron pan with avocado oil:

Step 1: Clean Your Cast Iron

Start by cleaning your cast-iron pan with hot water and a brush to remove any food particles or residue. Avoid using soap as it can strip away the seasoning. Dry the pan thoroughly with a towel or by placing it on the stove over low heat for a few minutes.

Step 2: Apply Avocado Oil

Using a paper towel, apply a thin layer of avocado oil to the entire surface of the cast iron, including the handle and exterior. Ensure you coat the pan evenly to create a smooth, non-stick surface.

Step 3: Remove Excess Oil

After oiling, use a clean paper towel to remove any excess oil. It is important to have a very thin layer of oil on the cast iron, as too much oil can result in a sticky residue after seasoning.

Step 4: Heat the Cast Iron

Place the oiled cast iron pan upside down in an oven preheated to 450°F (232°C). This allows any excess oil to drip off, preventing a buildup on the pan. Leave the pan in the oven for about an hour, then turn off the heat and let it cool completely.

Step 5: Repeat the Process

For best results, repeat the oiling and heating process several times. With each round of seasoning, the pan will develop a smoother and more non-stick surface.

Maintenance:

After each use, clean your cast iron with hot water and a brush, avoiding soap. Dry the cast iron thoroughly to prevent rusting and apply a light coat of avocado oil to maintain the seasoning. Store your cast iron in a dry place.

Re-season the pan with bacon grease

Re-seasoning a cast iron pan with bacon grease is a great way to preserve the finish and prepare the pan for cooking. Here's a step-by-step guide on how to do it:

Step 1: Prepare the Bacon Grease

Before you begin, make sure you have some bacon grease on hand. Cook a couple of slices of bacon to obtain the grease, and then strain and cool it to room temperature. Pour the grease through a fine-mesh strainer or a double layer of cheesecloth to remove any small particles that could stick to your pan.

Step 2: Clean the Pan

If your cast iron pan is new, clean it with water and dish soap, and dry it with a clean cloth before seasoning. For a pan that has been used, scrub it with an abrasive scrubber and dish soap to remove any stuck-on food or residue. Make sure to dry the pan thoroughly with a towel after cleaning.

Step 3: Preheat the Oven

Preheat your oven to 350°F (175°C). This temperature is ideal as it is below the smoke point of bacon grease, which is typically around 325°F to 375°F. Keep in mind that the smoke point can vary depending on the age and reuse of the bacon grease.

Step 4: Apply Bacon Grease to the Pan

Using a pastry brush or a paper towel, apply a thin coating of melted bacon grease to the entire pan, including the bottom, handle, sides, and interior. Make sure to cover all surfaces evenly.

Step 5: Bake the Pan

Place the greased pan upside down on the middle rack of the preheated oven. If your pan has a wooden handle, season it on the stovetop instead of in the oven. Place a baking sheet or a layer of aluminum foil on the rack below to catch any drips. Let the pan ""cook"" in the oven for one hour.

Step 6: Cool and Remove Excess Grease

After an hour, turn off the oven and let the pan cool down inside. Once it's cool enough to handle, remove the pan and rub it all over with a paper towel to wipe away any excess grease. Your cast iron pan is now ready for cooking!

Maintenance Tips:

To maintain the seasoning and keep your cast iron pan in top shape, follow these tips:

• Clean your pan after each use by wiping it with a paper towel while it is still warm. This will remove excess food and oil.
• Rinse the pan with hot water and scrub it with a non-metal brush or a non-abrasive scrubber to remove any stuck-on food. You can use a small amount of soap, but avoid harsh detergents as they can remove the seasoning.
• Dry the pan immediately after rinsing. You can also place it on the stove over medium-low heat to ensure it is completely dry.
• Lightly oil the pan after cleaning and drying. Heat the pan on medium-low heat, then add a small amount of oil and wipe the surface until it appears dark, smooth, and free of residue.

Frequently asked questions