smokinbarrel
Are you willing to share your formula for the rust bluing solution? Your formula containing both nitric and hydrochloric acids sounds like it might be similar to the LMF product. My supply of commercial products is getting a tad low and have not been able to find a Canadian supplier. International shipping is, apparently, not an option.
I have not experienced any color shift using baking soda or other base to neutralize the acid. I agree that prolonged boiling or steaming goes a long way toward eliminating the after-rust problem. However, that step must be omitted when browning, hence the need for a neutralizing agent.
I use the recipe developed by the old Neidner company in Dowagiac Mi. 2.5oz nitric, acid 2oz hyd. acid, 1oz wire nails, 30oz distilled water. That's a fairly big batch, you can half all those amounts. I put both acids in a glass jar then add the nails (outside) it is a violent reaction that gives off brown smoke. Once it calms down and nails are mostly eaten add the water. Keep in a dark glass bottle(preferably with a glass stopper). I bought a gallon jug of each of these acids many years ago, I don't know how easy it is to buy them anymore. I forget the exact % concentrations on them so you may have to experiment a bit and make adjustments with w/e is available. Book says leave it on for 3 hours, but I have run it as long as 6 without ill effects. I don't use any sort of damp box, so humidity conditions vary a bit. A note on degreasing; I wipe everything down with rubbing alcohol as a final step before applying blue and also after carding each time. Hard steel will often only need about 4 passes but typically barrels etc will take 6-8
You can overdo it, too many passes and the color will start to leave and surface begin to pit. With this solution there is no point in polishing finer than 320 grit as the solution lightly etches the metal. If done right, it is a nice matt appearance and quite durable.
A note on the nails; use soft plain steel, no galvanize or anything and smaller nails dissolve faster, rusty nails are ok too. Dump w/e is left into the final solution, they eventually disappear.
As for boiling, the book says 20min. but I usually only go about 10, the process seems to be fairly instant as soon as the parts get to temp they turn blue fast. I always let the water boil before putting parts in. On last pass I go about 20 min.
One other thing; Let parts cool before applying the next coat of bluing.