Surprised that petropatch didn't work for you as I've had very good results with it. My thoughts would be to petropatch the outside and then use one of the interior sealing products inside, sorry can't think of the brand name at the moment.
Many years ago I silver soldered a fuel tank after washing it thoroughly with detergent and ventilating it until I could not really smell any petrol, but I can see that filling it with CO2 would be a good precaution. To save the paint you can place a damp cloth firmly against the painted part nearest the repair.
Good luck with a tricky job!
Shaun
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