Removing rust ?

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I have an old motorbike tank and the fuel cap was left off whilst it sat in the weather for a year or so. The inside of the tank is covered in rust. Whats the best way of removing the rust cheaply and coating the inside with something to prevent further rust before I start welding some small holes that need repairing ?
Reply:Electrolytic rust removal is the way to go.  I won't be going back to wire brushes and phosphoric acid having tried this method.  You'll need a battery charger, plastic tub big enuf to submerge the tank and a length of sacrificial iron, like a piece of rebar, and some baking or washing soda.  Check out the details on the web, many places.  You may have finagle a little to get the electrolytic action working inside the tank.  It may turn it's necessary to put your rebar down the filler hole--just insulate the end touching the bottom of the tank with a bit of old garden hose, same where the rebar touches the filler hole going in.  I was skeptical of electrolytic rust removal, and put off trying it. But it really, really works.  Obviously, I'm an enthusiast.I guess you could also just fill the tank w/ a phosporic acid solution and wait.Good luck welding on the gas tank.
Reply:Clean out the tank with phosporic acid from the pool supply store and get a kit called  "tank Seal" from you local bike shop or the internet and you will be good to go.  The acid will clean and remove almost all of the rust and the sealant will fill ay pin holea and keep new rust from forming.  Pretty easy fix, just dont forget and leave the acid in the tank too long and make a bigger problem.  Hope this helps, and dont forget to install an inline filter to catch anything you missed in the tank.BobI'm spending my Kids inheritance, I dont like him that much anyway!!!!!!Enuff tools to do the job, enough sense to use em.Anybody got a spare set of kidneys?  Trade?
Reply:depending on the amount of rust I have used Evap-o-rust on lighter rust problems that i can let soakhttp://www.harborfreight.com/1-gallo...ver-96431.htmlTiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Please be careful with any coatings, if it comes loose it WILL plug the outlet. Makes a mess.Tim Beeker.
Reply:I Wish I Had Know About All This Fancy Stuff When I Was A Kid We Just Put Small Oval Shape Rocks ( jackrocks ) In The Tank And Played Catch For A While Then Washed The Tank Out With Kerosene - Works Pretty Good -  I Do Agree With Mr. Tnjind - It Will Come Loose Over Time And Create Another Mess - Good Luck
Reply:Vinegar will remove rust from sheet metal, Google it.... probably the easiest/cheapest way to remove rust on sheet metal.Lincoln pro mig 180Lincoln Square Wave Tig 300/wp 20/home built water cooler Victor, Purox, Harris, O/A welding/cutting setupsVintage Craftsman drill pressVintage Craftsman/Atlas 12"x 36'' lathe7''x 12'' w/c band saw Everlast 140 st
Reply:Fill it with BB's and some sort of non flammable solvent and shake like hell.Yakdung
Reply:This is what I love about forums like this and others, the greta advice that previously was unknown to me. Thanks everyone for the help, and I am sure after a little bit of investigation after the x-mas break and I will try one method and report my result beck here.Great christmas break everyone, and don't forget  -- If you drink - Don't drive !
Reply:+1 on electrolysis worked great on my shorthood tank.http://www.rickswoodshopcreations.co...st_Removal.htmWhen any government, or any church for that matter, undertakes to say to its subjects, "This you may not read, this you must not see, this you are forbidden to know," the end result is tyranny and oppression, no matter how holy the motives.
Reply:In the old days I used ball bearings.  Today I'd probably goes with electroylsis (sp). Originally Posted by RenagadeI Wish I Had Know About All This Fancy Stuff When I Was A Kid We Just Put Small Oval Shape Rocks ( jackrocks ) In The Tank And Played Catch For A While Then Washed The Tank Out With Kerosene - Works Pretty Good -  I Do Agree With Mr. Tnjind - It Will Come Loose Over Time And Create Another Mess - Good Luck
Reply:I agree with electrolysis. There are a few threads over on PracticalMachinist about it if you need more info. Electrolysis isn't the quickest way to go, but if you have the time to set it up in a plastic tank for a few days-weeks (depending on the amount of rust/paint/grease/etc.), then it works quite well. Keep in mind that depending on what the piece is made of, it may rust very quick when you take it out of the solution. (Cast Iron rusts within minutes!) I spray the piece down with C.L.R. in a spray bottle and it keeps the rust away. Once the CLR is dry, I paint.For cleaning the inside of a tank, you might want an extra electrode inside the tank to help attract the crud from inside. Just make sure that the electrode doesn't touch the tank itself, or you'll fry your battery charger.AndrewP.S. My electrolysis tank is going full tilt right now cleaning up my radial arm drill. See my thread over on PM - same username.Last edited by Andrew_D; 12-17-2011 at 02:46 PM.
Reply:This is what you are looking for:http://www.por15.com/CYCLE-TANK-REPA...ductinfo/CTRK/This is what I use on all my bikes, and have had no problems so far, and it's been 17 years so far. I have heard of nightmares using Kreem tank sealer, but not this stuff. This stuff kicks a$$.kidtigger24  They think I’m crazy, but I know better. It is not I who am crazy. It is I who am MAD!
Reply:Where are these hole located? Are they in the area where the water collected (bottom of tank)? I think the rust would be the least of your worries. I think you should poke around the bottom with an awl and see if you can find any more weak spots first before moving on.