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I am in the process of restoring my heater box, sponge seals etc. All trial and error. It is not such a big job to remove just a pain if the sponge seals happen to be glued to the metal. It is amazing how much crap has accumulated in there over the 37 years including rust. I am of the opinion do a good job in the first place and you should not have to revisit for another 10 - 15 years. Any bare metal I am treating with a rust inhibitor then painting. This would be the case for you surface rust problem which will turn into a major rust problem in a few years. All the best.
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