That's a cool little jeep. Your best bet is to blast the rust spots. Any other way your taking what metal you have left and thinning the area. only other thing to do is cut it out. You shouldn't worry about working around the gas fumes with a wet rag and a blaster you will be fine. It's sparks and fumes that combust. Look for a speciality place online more then likely they will have your patch panels for that truck. Take your time and research and practice it's the only way to learn. We all started with the same knowledge and experience as you. Just takes practice and time. Good luck

Put a ground wire on the truck and static will not be a problem.
Also, if you are concerned about flammable vapors, put a small fan on low right near the area you are working on to flood the area with fresh air.

do what these guys have said and use the spot blaster. if your really worried about the gas fumes you can shoot the tank full of CO2 from a fire extinguisher be sure its CO2.
Jay D.

I dunno if I would use CO2 from a Fire extinguisher kinda hard to regulate lol but if your really worried just pull the Tank easy enough to do not hard at all.

The tank is rusty, if I disconnect or remove it, the connection pipe will likely break off.

sounds like maybe you should replace the tank.
Jay D.

I doubt very seriously it will break Its supposed to come apart and if its rusty it should be replaced any way probably has more rust inside than out side, Today's Fuels attracts Moisture quickly.

I have not tackled the project any further yet.

There are two small dents to the right and above the rust patch. After I tackle the rust I'm going to bondo over the two small dents. I have an Onion board and Durablocks on their way to me. I already have some etching primer and primer sealer. I know I have to use the etching primer over bare metal but can I use it over bondo too?

What grit of sandpaper should I buy for sanding over bondo? I'm going to buy maybe two different grits, one for over bondo, and then one for sanding over the high build primer.

Thinking 180 or 200 for sanding over bondo and 320 or 400 for sanding over the primer to prep for paint. Thoughts?

200 sounds good for the bondo. And i would stick with 400 over the primer right before paint.

dainternetguy wrote:I have not tackled the project any further yet.

There are two small dents to the right and above the rust patch. After I tackle the rust I'm going to bondo over the two small dents. I have an Onion board and Durablocks on their way to me. I already have some etching primer and primer sealer. I know I have to use the etching primer over bare metal but can I use it over bondo too?

What grit of sandpaper should I buy for sanding over bondo? I'm going to buy maybe two different grits, one for over bondo, and then one for sanding over the high build primer.

Thinking 180 or 200 for sanding over bondo and 320 or 400 for sanding over the primer to prep for paint. Thoughts?

You're going to want more than 2 different grit sandpaper on hand. Generally you'll block or DA your filler with 80 grit then follow with 180. Prime, guide coat then block with 240 or 320. If needed prime again, finish with 400-500 wet to prep for sealer.