On advice of a Samba forum post, I took a closer look beneath the headlights. The driver's side is fine, but the passenger side had a tiny discoloration (sorry, no 'before' photo) about the size on a pinhead. Here's what the 2x3 inch area looked like after hitting it with the wire wheel...
Here's an area behind the wheel on the passenger's side. It also started out as a small blister before the wire wheel... now its an opening about the size of a golf ball.
I got some 40-mil aircraft-grade '4130' sheet metal from McMaster-Carr for about $38. The cost also includes angle iron I will use to make a Type III pulley wrench (from the Muir Book) and shipping.
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