Ed, BTDT many times in my shop.  You cannot repair the rust without removing the windshield.  The rust is in the two corners for sure and maybe more.  If you cannot remove and re-install the windshield have an auto glass specialist do it for you.  My preferred method of repair is to use POR-15 <http://www.por15.com/> and if there are holes that need patching, I use POR-15 with Fibreglass.  Follow the directions from POR-15 for priming & painting.  When re-installing the windshield either clean the old seal well or get a new one.  Coat the seal liberally with a good Rustproofing oil such as Krown that we have here in Canada.  Also coat the windshield frame with the same oil.  

> On Apr 8, 2016, at 11:30 AM, Automatic digest processor <LISTSERV@GERRY.VANAGON.COM> wrote:
> 
> 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?

      Please note that I will be away from my business travelling from November 16 until April 30, 2016.  Parts orders will be processed although not as quickly as usual.  I will always be available for contact by E-mail.  If you phone your call will be addressed by Steven and he will either call you back or advise you to contact me directly by E-mail.  

Cheers, 
   
Frank Condelli
Almonte, Ontario, Canada
'87 VW Westy, '00 Kawasaki 250 Sherpa, "98 Ducati 750 Monster & Lionel Trains (Collection for sale <http://frankcondelli.com/trainsal.htm>)
Frank Condelli & Associates <http://www.frankcondelli.com/> - Vanagon/Vanagon Westfalia Service in the Ottawa Valley
BusFusion <http://www.busfusion.com/> a VW Camper camping event, Almonte, ON, June 02 ~ 05, 2016