I tried the putty, but it would simply start in another place. Back on the east coast there was a process called "gas tank renu", and that's what I did for BII's rusty tank. Not sure if we have such a thing out here? What they did was coat the tank in a resin, and then bake it. Tank came out looking like new. And no more leaks.

Praps you could shoehorn a genII tank in there while you're converting other goodies... <img src="/forums/images/graemlins/wink.gif" alt="" />

In terms of pressure, what does the tank do when you're filling it up - does it spit fuel at you at the last second before the gas pump kicks out? Just wondering if you have a kinked vent line? Never been any vapor lock, has there? Don't recall...