First check for fuel pressure. If you have none, you likely have to fill the tank more. There is usually a small pot inside that the pump sits in. Return fuel keeps it full when the fuel level is near empty. That's to prevent the engine from dying out on corners when the fuel level is low. If that pot is empty, there's no fuel being pumped to the engine, and no return fuel to fill that pot.
Also listen for the hum of the fuel pump to be sure there isn't some other problem. It should run for one second after turning on the ignition switch.
If you sanded the "shiny" off the tank before you patched it, that patch is likely to be permanent. I used Chrysler's gray RTV gasket sealer on my '88 Grand Caravan over 20 years ago after Ma hit a chunk of steel in the road. The hole was three inches by two inches. That lasted until last year when the tank rusted though in other areas.
If you DO replace the tank, get a second opinion from an independent shop. My steel tank cost less than a hundred bucks from eBay, and the job took about an hour with a hoist. One reason I like my rusty, trusty van is parts are cheaper than for newer vehicles, but a thousand dollars seems awfully high.
Sunday, July 27th, 2014 AT 8:54 PM