Had one out of round radius arm hole to deal with.  Was able to put a moon shaped fill weld in there and with a bit of filing and grinding get it looking ok.
Here are the pics:

http://picturepush.com/public/12541608

http://picturepush.com/public/12541610

http://picturepush.com/public/12541611

http://picturepush.com/public/12541612

http://picturepush.com/public/12541613

http://picturepush.com/public/12541614

http://picturepush.com/public/12541615

http://picturepush.com/public/12541617

http://picturepush.com/public/12541618

Also installed powerflex bushings 
across the whole front end.  After a realignment the van drives much 
nicer.  Install was pretty well described in other archived posts.  
Rears are a piece of cake, fronts some fooling around.  Only thing I 
kind of screwed up was at one point I let the front end 'hang' from the 
upper ball joint (ie spring in but no shock installed).  Later read the 
bentley that is a no-no.  Otherwise time consuming but fun.   Lots of 
stopping for day here and there to get the unexpected.....14x1.5mm nuts 
that were wrecked....wait for tie rod ends to come in the mail since old
 ones were destroyed during removal, etc etc.  list goes on.  Got there in the end.

Brett
91 Vanagon with 2.2L subaru
Vancouver, BC