It can't be done, most of the rust is up under the rubber and will return in a year. If you leave it or attempt a repair, you'll likely have a hole under it soon.

If your windshield is new or in really good shape you can cut it out by cutting the inside of the rubber seal off around the inside edge.  New seal is $40 for the plain rubber version, but unless you know how to install it, have a pro do it.

If your windshield is original, just replace it and the seal.

Stuart 

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of ed donnen
Sent: Friday, April 08, 2016 4:07 AM
To: vanagon@GERRY.VANAGON.COM
Subject: rust under windscreen

So here I am again, wrestling with the rust demons.  I tried to take an evening auto body  class, but the equipment was all broken, so I dropped out.
So my question- Has anyone tried to fix the lower rust problem below the windscreen WITHOUT removing the windshield?  Removal kinda scares me.

Thoughts?

ed-91DoKa, with rust, again