Ive used POR15 to a tank 15 yrs ago and its still ok
Getting it rust free is the issue
I used small stones that are for sealing road chip nice and hard with sharp edges then shake and shake wash out and repeat
Maybe gives a good finish for paint to stick.
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Hi Norman, I’ve just been to Daventry metal finishes they said they can remove the rust but they wouldn’t nickel plate it.. as there is a high chance the nickel will come off… might just have a go at lining it myself with the por15
Ah, sorry for the misdirection Sean
That’s okay the guy did say that the bloke who probably did it has left now… not a wasted journey at least I can get all the tank cleaned up 
thankyou
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Hi Norman, look at a company called motorcycle dent removal in Yorkshire they specialise in nickel plating inside a fuel tanks and dent removals amongst other things… I have mentioned the piping and metal mesh inside and he said that won’t be a problem… worth a look
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Hi mollrs, thats good info, I think ill give them a try on the next tank I do. 
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Hi Sean
That’s the issue, getting the thing clean. I hooked it up to a battery with the negitive end on the tank and the positive to an iron rod to attract all the rust. It worked for a while, but there was too much of it. I shifted to vinegar and then finally a quick wash out with acid, and I mean quick. it flash rusted as soon as I left it for a few hours even after putting some two strike oil inside. I’m going to give it the full POR15 treatment and see if it will stick to the inside after their cleaning process.
It has been a bastard, but at least I finally got all the big chunks out of the corners. A new tank is hundreds in Australia if you can find one.
Rod
Hi rod after all the issues I’ve had with bike the tank has been the most challenging.. getting rid of the rust is key 
.. I’m taking the tank to get nickel plated in a few weeks so I’ll post some pics of the end result.. thanks for the info
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Hi i will post some pics when i get mine done in a few weeks
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I ran the POR15 motorcycle kit through the tank with the addition of 500ml of hydrochloric acid for about three minutes. Then the sealer. It was barely enough to coat the inside of the large tank. I would consider the standard tank kit, and have too much of the coating it would be better to have too much than too little. This has easily been the hardest thing I have had to deal with on my bike.
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Hi Rod, I agree about how hard it is to fix rusty R tanks. As you realise it’s made much more difficult by these tanks having no drain plug, or even a gauge sender to facilitate draining like the F models have.
I was so frustrated trying to fix leaks, after removing the rust, plugging leaks with JB weld, lining the tank, only to find it still leaks……
Took 2 tanks to a brilliant restorer, but he has just let me know that they are both beyond repair. My last hope is one of two tanks I recently bought sight unseen, owner tells me one is good and leak free.
Fingers crossed that this one is workable?
I then need to learn how to fix these other tanks, which will probably involve adding drainage bungs, and repair by TIG brazing with BronzeAl filler.
Hi, I’ve have the same issue with my tank.. it had a old liner in there that had all fell away and a lot of the tank inside was full of rust… I took it to a fantastic guy who’s a tank specialist in Yorkshire… I had the liner removed, all the rust removed and seemed clean… I had a drain hole put on the bottom of the tank with a stainless steel bung fitted.. then the tank had 25 µm of nickel plate on the inside… I had loads of pinholes which are now all repaired with silver solder… it’s at the paint shop now being sprayed. I’ll send some pictures of the bung and the inside when I get it back the bloke did a fantastic job but he did say it was one of the worst tanks he’s ever had to repair….
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