Hi Neil.  I was able to pressure test it this morning, got quite a few PSI in there and there were no pin leaks.  Rust chips are pretty large in the area where I have the rust patches - im worried if I work it back to clean material I will have a very thin walled tank in that area.  Im also scratching my head as to what tool to use - normally I would just hit it with the angle grinder....probably not a good idea in this case.  My electric wire brush isn't quite cutting it.
Maybe i'll just brush the loose stuff off and try your rust inhibitor trick.
Brett

> Date: Sat, 12 Mar 2011 23:27:52 -0800
> Subject: Re: Surface Rust on Gas Tank (with pics)
> From: musomuso@gmail.com
> To: rueffy@hotmail.com
> CC: vanagon@gerry.vanagon.com
> 
> Just a WAG, but looking at 2nd image, my first reaction is that you
> may find pin holes in that tank. If I found pin holes I'd toss it. But
> that's just me.  :)
> 
> There are rust inhibitor sprays that should slow down the rust some.
> When I'm "under there" I spray Rust Check (crappy tire) at harder to
> get at areas in hopes that it'll work it's way between parts that are
> tack welded in place. Where possible, I remove the loose rust and
> paint on inhibitor.
> 
> Neil.
> 
> On Sat, Mar 12, 2011 at 9:57 PM, brett rueff <rueffy@hotmail.com> wrote:
> 
> 
> > The tank has some surface corrosion in a couple of patches.  Other than these two areas tank appears in good shape.  Inside looks excellent.
> > I think its worth tying to save.  Any suggestions for dealing with the surface rust?  Wire brush, prime and seal?
> > I have some minor surface rust starting in the cavity where the tank sits.
> 
> > Heres my pics: http://www.flickr.com/photos/55896090@N04/sets/72157626253934738/
> > ThanksBrett91 Vanagon.  EJ22.  Vancouver, BC
> 
> 
> 
> -- 
> Neil Nicholson '81 VanaJetta 2.0 "Jaco"
> 
> http://tubaneil.googlepages.com/
> 
> http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines