I saw a guy do an interesting repair on this kind of damage once. They
ground out all the rust, and he then re-established the top edge-line with a
very stiff/strong piece of steel wire. Then they filled the small (say
pea-sized or smaller) holes and welded in metal strips of around 3/8"
between the wire and the panel where the larger pieces had rusted away. When
they were done they had mostly new metal and a nice clean edge. After it was
finished and painted it looked perfectly normal and it was sound. With the
window back in you couldn't tell what if anything had been done.
I have no idea if that's according to Hoyle but it worked great.

Cya,
Robert

----- Original Message -----
From: "Jens Jakob Andersen" <jayjay@ZORCK.DK>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, April 18, 2006 5:28 AM
Subject: Temporary fix for rusthole under window?

> Hi
>
> The latest bus,
> http://www.zorck.dk/cara3/
> have some holes under the windows, below the rubber.
>
> Small holes -4-5 mm across (yet).
>
> I know that proper fix is remove window, weld, replace window.,
>
> What are the best ways to intemediate fix?
>
> It will have to work for some months.
>
> Remove rust the best I can.
> Rustproofing, Tectyle or Dinitrol.
> Silicone to make it watertight
>
> was my plan.
>
> Any other suggestions?
>
> Long term plan:
> * Remove windows on blue van (train in removing windows).
> * Cut out parts of the windowframe, for the welder to work with on
> the yellow one.
>
> Happy driVWing
>
> Jens Jakob