Thanks for sharing Neil,
 
The good news is that I don't have nearly such a challenge.  So far everything I've encountered is surface pitting.  I'm guessing that the worst location I have today is on the insie of the rear window seal, but after close inspection I think I'll be able to grind it out and treat it.

--
Matt Thyer

----------------------------------------
> Date: Thu, 25 Feb 2010 12:26:59 -0800
> Subject: Re: POR 15 in the seems
> From: musomuso@gmail.com
> To: matt_thyer@hotmail.com
> CC: vanagon@gerry.vanagon.com
>
>
> People have done this and there should be lots in archives about it. :)
>
> My own seam experience (prior to getting hip to POR) started with the
> PS rear fender area. I literally scraped the exterior seam down to
> bare metal, prepped and painted with generic rust paint. So far so
> good. Down the road, I treated the "kitchen" seam with Plastikote. Did
> my best to get at the inside of seam while fridge was out.
> http://sites.google.com/site/tubaneil2/kitchenrust%21 Quite literally
> sealed up the seam with it. (no pic of that) Still holding AFAIK. Not
> pretty, not pro, but hopefully holding rust at bay for a while.
>
> Proper prep aside, the trick is to get at inside of seam too (though I
> know you specified exterior)
>
> Neil.
> --
> Neil Nicholson '81 VanaJetta 2.0 "Jaco"
>
> http://tubaneil.googlepages.com/
>
> http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines