A few questions

I am looking into a few options on my what to do with my tank which is somewhat rusted on the inside and definately needs paint on the outside.
The all in one solution is to order a new tank OEM for $237, however I am a mere college student.
Any Ideas on treating the inside, and painting the tank?

factor into the equasion that I am still in need of sidecovers, what are my best options?

I am affraid if I paint the tank myself i will be unable to achieve the slight blue sparkle in the paint to make the bike look original.

Also, anyone have any advice on saddlebags for longer trips, or Windshields?

 

If You go to any good auto parts storeyou can get the original yamaha blue/black mixed,usually in a spray can. I worked in an auto parts store myself, and thats exactly what I did

 

Electrolysis works very well to clean out the internal rust. You should find it easily on the web, but briefly...

Don't quite fill the tank with water... add some washing soda (sodium carbonate)... immerse something ferrous into the tank but NOT touching it at ANY point... let it protrude out... connect + of a 12v charger to the ferrous object... - side to the tank... let it cook !

You'll possibly need to give it a few applications. I did it, giving quite a few applications over a weekend. Can see clear metal now. No problem.

 

I've heard tell that CLR cleaner sloshed around in an empty tank for about a half hour removes all traces of surface rust. But you will need to wash it out carefully afterwards and slosh around some oily type fliud (diesel) to apply a thin rust preventative coating on the fresh metal suirface or it will start forming new rust in mere minutes

 

Sudco sells a chemical rust remover. It is available at most bike shops and on line. I would suggest that you avoid using CREAM, most folks do not do it correctly and I've had to try (operative word here is try) to salvage the carbs after the goo oozes down and clogs up the jets and passages. The electrolysis method outlined on the forum works well from all accounts (yet to do it but am inspired to, someday soon maybe). Don't be in a hurry to paint the tank. Any painter will tell you that a good paint job is 99% preparation and that isn't any joke. Clean everything and learn to wet sand the finish and buff it out to a beautiful shine. You should be able to paint your own tank for less than $80 in materials and paint. A new tank for under $400 is a good deal FYI, wish they would sell mine for that much.