In a message dated 12/08/2009 11:08:17 P.M. Eastern Daylight Time,
LISTSERV@GERRY.VANAGON.COM writes:

        Pete, use POR-15 to glue  the new metal to the rear of the old
metal.  Hold in place with countersunk  pop rivets.  Works perfectly and better
than new when done right.   Follow the directions from POR-15.  Very little
filler needed, I use  Polyester filler, made for this purpose as it can be
used over painted  surfaces.  See photos here of some jobs I've done in my
shop   >  _Vanagon Body  Restoration_ (http://frankcondelli.com/vwpics.htm)

>>>>>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.<<<<<<

Cheers,

Frank  Condelli
Almonte, Ontario, Canada
'87 Westy & Lionel Trains (_Collection for sale_
(http://frankcondelli.com/trainsal.htm) )
_Frank Condelli &  Associates_ (http://frankcondelli.com/busindex.html)  -
Vanagon/Vanagon Westfalia Service in the Ottawa Valley
_Vanagon Stainless Steel Exhaust  Systems_
(http://frankcondelli.com/exhaust.htm)
_BusFusion_ (http://www.busfusion.com/)  a VW Camper  camping event,
Almonte, ON, June 11 ~ 14,  2009