54 Chevy headlight
54 Chevy headlight
54 Chevy headlight
I took care of the rust using the same technique as described in the Fuel Tank section: concentrated hydrochloric acid, and a lot of nerve. Seriously--I don't recommend that you do this; it's really dangerous. But--wow! You can see the rust disappear in minutes.

Gray primer and a new gasket finished the job.
Original rusted part
After acid cleaning and fast etch.
After a coat of gray primer.
54 Chevy headlight