Don't like sitting immobile again after a day of riding this week so I researched the rust rectification methods here and found three- Electrolysis, coatings, and the Naval Jelly method.
I am going to try all three and report on them eventually. But for today I am going w/ the Naval Jelly method because it's the fastest. It promises to make me drivable in three hours! The other two methods each take DAYS.
Here is my shopping list. I am heading out to pick it up.
50 1/4 steel nuts
12 oz. Muriatic Acid
Good quality duct tape
1 Small bottles Naval Jelly (Made by Loctite it appears)
Telescoping Magnet (optional)
And a bucket and garden house are also required. I have those on hand.
Will keep everyone posted how it all goes. Below is a cut and paste from Fergy's post with the instructions I am using.
You have to remove everything, petcock, fuel level sensor, gas cap etc. and tape up every opening with good quality duct tape. Use a handful, maybe 50 or so, small 1/4" nuts and dump them into the tank. Carefully, pour about 12 oz of muriatic acid (they sell it at pool supply stores, or Home Depot) into the tank and tape up the gas cap hole and shake the tank vigorously for about 10 minutes. Keep the garden hose handy and rinse off any leakage immediately. (wear old clothes, rubber boots, rubber gloves and eye protection, maybe a smock if you have one) The acid and nuts will eat the rust off the tank inside. You might have to vent the pressure off the tank by lifting the tape around the gas cap hole every once in a while. You'll know when it bulges the tape. Keep rinsing the outer surface immediately if any acid leaks out around the tape. It will be the color of mustard so it's not going to be hard to see. After 10 minutes or so, remove the tape and let the acid drain from the bottom of the tank, into a plastic bucket full of water that you have added about a cup of baking soda. The baking soda will neutralize the acid. The writeup said to pour the acid on a patch of old concrete that you don't mind staining to neutralize it, but I prefer the baking soda method. Then you can pour the mixture in a gravel or dirt area and it will be fine. This acid will etch the metal and your surface will be clean and rust free. Now rinse the tank very well, flushing it with the hose and shake it to make sure you get all the acid rinsed out. You can use a telescoping magnet pick up tool to get all the nuts out of the tank. (make sure the nuts are steel!) Then tape it back up and pour two small bottles of naval jelley into the tank. You need to do this immediately after you get the acid flushed out, as rust will start to form immediately on the untreated metal. Shake the tank for a minute or two and then let it set for 30 minutes, then shake it again. Do this for 2 hours. Then rinse the naval jelley out by flushing it with the hose. Once clean, dry off the outside and rig a blow drier at the warm, not hot, setting and let it dry the inside of the tank. The phosphoric acid in naval jelley will treat the metal and make it resistant to rust. My tank has been silver inside since I used this to clean it.
It's messy to do, but it works very well, and doesn't leave a film inside the tank that you might have problems with later. This method might seem a little radical, and some of you might prefer not to mess with the acid, but it works very well.