Most Vanagons get the rust on the front lip. Wire brushing and POR 15 treatment every few years has slowed down the rust for me, but it keeps coming back.

Like Neil I was also wondering when it becomes a structural problem.
I don't have a large hole like you, but I think the joint between the front sheet metal and bumper may be weakened by the rust. Water comes in from behind the radiator and bubbles any paint I put on it... :(
I also tried to wirebrush and paint the inside, but apparently didn't manage to stop the water.

Martin

--- On Wed, 8/12/09, Pete Geisen <geisenpa@GMAIL.COM> wrote:

> From: Pete Geisen <geisenpa@GMAIL.COM>
> Subject: 82 Westy body rust fixes
> To: vanagon@GERRY.VANAGON.COM
> Received: Wednesday, August 12, 2009, 5:56 PM
> Hey all, I've been doing some
> searching on how to repair rust damage,
> and I'd thought I'd get some of your input, as I'm sure
> most of you
> have seen this at some point (though probably not to this
> degree). A
> couple owners back for some reason had a piece of foam
> rubber just
> behind the front end, under the radiator, I'm assuming to
> try to stop
> vibration. Dumb idea since the stuff loves to soak up
> water. In any
> case, I am left with a 2.5ft x 2" rusted out hole in the
> front behind
> the bumper that is slowly creeping out. Here's the shot:
>
> http://geisenpa.home.comcast.net/~geisenpa/vanagon/frontbumper.jpg
>
> I'd really rather not have to take it to a body shop,
> though I know
> that's probably the answer (not trying to mistreat the old
> girl, just
> low on cash, looking for other options). Wondering if any
> of you had
> DIYed a hole this size. I don't have a welder, so that's
> out. Would
> cutting out the section and JB welding some sheet metal do
> the trick
> (with some serious patching), POR15 and painting and all
> that? Any
> tidbits from you guys would be greatly appreciated. I'm
> tired of
> looking at that gaping hole.
>
> Pete
>

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