I noticed the same problem with my EGR filter; the entire bottom of the
filter had rusted through on both sides, though there was plenty of good
metal above and below the rusted area.  So I got a couple of packages of
that "muffler putty" stuff at my local flaps and went at it, following
the directions implicitly, and darn if it didn't turn out pretty good!

You can smooth this stuff out pretty well (I think you're supposed to
mist it with water) and it dries a kind of grey color that actually
blends in fairly well with the EGR.  In my case, you have to look closely
at the EGR (and know what you're looking for) before you even notice the
repair.  As far as I can tell everything's working all right, and the
"fix" was considerably cheaper than a new one at the dealer.  As I recall
we're talking 3 figures here for a new filter!

On Thu, 13 Aug 1998, David Chasteen wrote:

>While putting the new cat on, I noticed that the EGR filter had rusted
>out in one corner.  I checked our favored vendors, but none listed the
>EGR filter.  Called my FLAPS, and he did not list an aftermarket EGR
>filter for the 82 Vanagon.  Can anyone steer me to where I can get one,
>other than from the dealer?
>
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Tom Young               young@sherlock.SIMS.Berkeley.EDU
Lafayette, CA  94549    '81 Vanagon
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