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Here are a few photos of my recent gas tank restoration.  My tank was a real wreck with severe rust pitting where the mounting straps went.  You could see daylight when looking through the filler neck.  Try as I might I couldn't find a suitable replacement.  That left me no choice but to weld on patches.  Welding on a gas tank isn't exactly a good idea so you can imagine I was pretty nervous.  To prepare the tank I cleaned it up, rinsed it several times, blew a lot of compressed air through it and then filled it with argon.  Everything went well and I didn't blow up.  I will be lining the tank prior to installation.  Enjoy the pictures!

 

 

Looks great! Excellent job, and congratulations on not exploding.

This is awesome, great job!  What are you coating it with?

That looks great!  I've sealed 2 with Red-Kote, it's much easier and cheaper than the Por-15 sealer.  $30 at local auto parts store, O'Reilly's, or you can get off e-bay.

This is awesome, great job!  What are you coating it with?

POR-15.  I may paint it again to flatten it some.  I just wanted to be sure to kill all of the rust.  

Very nice job, congrats

I had my gas tank repaired recently. Although not as bad as yours, and didn't do my own repairs, it came out great! Had the tank cleaned and sealed, and the shop I took it to soldered, not welded, all the pin hole leaks. The tank had some small dents, but after having it coated with Line-X, it came out great!

 

 

 

there is still one dent on the tank however, but shouldn't be too noticeable given where its located.