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It varies by the size of the journal as I remember. Find an older Motors Manual. It has information on plastigauge use and bearing clearances, maybe on the engine you are working on.
Your plan is good. After washing, treat the tank with Ospho or something similar.
Weld the tank back together and coat with GOOD tank sealer. You'll be golden.
See one of my previous post about sealing Jerry cans.
I know it will be a pain, but pull your starter and check the stroke of the solenoid fork. May be grunge or rust causing it to not move the pinion into engagement. If the truck will always start after a few tries, I'd live with it for now.
Don't even think about making dummy HazMat stuff! You will have BIG problems if you are questioned.
This is from my perspective as a volunteer fire fighter.
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