Bob, it's funny you mention that because the bike I did this on is the one that had the leaking filler bung: 0333. We had a discussion about it four years ago:
http://www.ehforums.com/ehwebsite/forums/index.php?topic=850.msg2291#msg2291Since looking at my other bikes, the glued-in plug was an early bike thing. 0738 and all of my later ones have solid, one-piece openings (no glued plate). I fixed that leaky plate with fuel tank epoxy. Never had another problem as far as fuel leakage goes.
The paint was another issue though. With fuel getting up to the rubber gasket and marinating the edge of the paint in it, the clear and some of the black were destroyed.
I just finished with the paint restoration on that one. Pics attached. It was pretty bad but, I managed to save it. The repair got pretty far out into the black. Every time I tried to feather the black fill into the factory clear, more would cleave off, flake and leave another hole. That continued for quite a ways toward the decal.
Eventually the repairs hit solid clear. It was black splotches, bordered by factory clear. After color sanding the rest of the tank to 1000 grit, I put maybe 5-6 coats of House of Kolor show clear over the entire tank. Let it dry for a month and color sanded last weekend. The results are just as good in person as the pictures show: no visible repairs.
