Fuel tank leak repair on a budget?

My new 900 has a rust spot looks to have started outside in. The guy stored it outside uncovered for a long time. It's leaking, though slow. Interior is clean. A decade ago I tried jb weld and it never held. But after cleaning that up I had way more damage to that tank, like a dozen holes within 1sq inch.
I can not afford the $300+ to have it fully sandblasted and repaired. Any suggestions? Pic attached.

 

caswell-epoxy-gas-tank-sealer-motorcycle-kit-up-to-10-gal-cans.html
You'll still have to do the paint if you want it to be pretty.
My test for that is to ask myself, "Can I see it while I'm riding?"
If the answer is no, then I leave it looking ugly.

 

Three of my tanks are rough looking so I am getting a tank cover made out of an old coat which will also protect my best tank when on long journeys. The manufacturers tank covers at a bit expensive in my view. I will post another picture of the cover when it is finished.

 

I am the same a bit short of cash at the moment too. My spare tanks need repairs also and I was thinking of a tank sealer for my good tanks, not sure what to do though. I have heard good reports about carswell tank sealers and POR 15. I wish I had the skills this man has at fabricating tanks, watch the video on the following link. What a craftsman he is.

 

So that sounds better then the kbs coating I used ten years ago Thicker, more apt to seal that hole from the inside out.
Can the Yamaha lettering be removed? If I'm going to do this I'm going to want to strip the entire tank. Or should I just wire wheel all the lower seams since there is no rust above that , and prime over everything letters included?
Then hand paint the face of the letters?

 

The Yamaha embem is held on in a couple of ways. Remind us which model you have. I'm assuming Seca 750 based on the rear of the tank. If so then you'll need dental floss and a hair dryer to cut the adhesive.

 

You might want to look at Caswell gas tank sealer. It was recommended to me by a good friend. This stuff should take care of your problems. I was told it is so good if you have holes in your tank it will fix it and you can smooth out the outside and paint it. Will not work if your tank has been sealed by any other method first. Looks like the interior gets very hard when cured. I bought some, but I didn't need to use it on the tank I bought it for.

 

Caswells sells a kit to remove all but the other brands of epoxy liners (and epoxy liners don't fail unless the prep-work was done incorrectly). So if a tank was done with Red Kote (for example) it can be re-lined with the Casewells kit.

 

Lead 'solder' repair?

 

'83 900

 

So caswell has now been suggested twice. Seems because it's epoxy style it is more likely not to leak out itself and properly seal, while also going on thicker.
Just a note, it is not lined at all and looks quite good inside No rust at all, and just some slight discoloration about halfway down.

 

K-moe do you know how these are attached?

 

The other option is to remove the rust and braze the holes shut, then re-paint.
That will cost less if you know how to do the work and already have the equipment, otherwise Caswells is the more cost-effective method. Lining will also prevent the tank from rusting further. You do have rust inside of the tank, you just can't see it because of where it is (down in the corner, where all the exterior rust is).

 

If you don't see any external screws on the emblems, then they are held on by adhesive.

 

Thank you sir!

Does this thought process make sense, budget wise?

Wire wheel visible external rust/paint.
Caswell (whole process right down to the nut and bolt shaking)
Paint over exposed metal from wire wheeling.

Eventually use aircraft stripper to clean down the whole tank and repaint correctly.

Think the stripper would eat through the caswell where the hole is?

 

Great plan. Caswell's is an industrial epoxy (supposed to be the same as is used on commercial fuel storage tanks) and paint stripper won't touch it.