I think you're already past this point in the project, but I had meant to mention that I had a similar experience with flash rust after using vinegar. I ended up using a small amount of Evapo-Rust to get rid of the flash rust. It took lots of shaking and sitting on one side, then the other, etc. but it did work. Then, to prevent flash-rust I drained the Evapo-Rust and put a bit of motor oil in, sloshed around, drained well. Then put some kerosene and a bit of fogging oil and it's been sitting that way for about 4 months and is still rust free. I plan to drain that before I fill full with gasoline, I don't know yet, but I suspect any residual "additives" will be diluted enough to not cause any issues.
If I had it to do again, I would have used phosphoric acid instead of Evapo-Rust as the final rinse. I think you're supposed to be able to rinse with that, then let it dry. At the time, I couldn't find any phosphoric acid, but have since found an easy/inexpensive source for a smaller amount of it: Krud Kutter RX32 Rust Converter.
If I had it to do again, I would have used phosphoric acid instead of Evapo-Rust as the final rinse. I think you're supposed to be able to rinse with that, then let it dry. At the time, I couldn't find any phosphoric acid, but have since found an easy/inexpensive source for a smaller amount of it: Krud Kutter RX32 Rust Converter.
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