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Whether the rust spreads inside the pony really depends on how damp it is inside her. It's not a guarantee that a pony with tail rust will have it spread.If you do replace the tail washer, be aware that the tail clasp does NOT rust, so you don't have to replace it. Personally when I replace a washer, I use rubber washers of a similar size (from the hardware store). To me that makes more sense / seems more secure than zipties.
I don't take off pony heads, pretty much ever. I've also got plenty of ponies who have a tiny amount of tail rust and have been so since the late 1990s without any change whatsoever. I think that keeping a close eye on it is important, and not letting it stay in damp conditions is also key. But it isn't a guarantee that a pony will get worse. In fact, the ONLY example of that happening among my ponies was in one of my flat foots, who have bigger and heavier washers anyway. I feel like taking the head off and replacing the washer is sometimes like replacing the windows in a house by knocking the house down. But this is a personal choice, just there are plenty of people who would see removing the head and esp. the tail washer as pretty destructive in its own right. It's a matter IMO of deciding which is more destructive overall, and that's a case by case judgement.Sea pony tail weights are another matter, as they've frequently been exposed to water and thus the damage can be much worse, especially the white ones. But whether to remove the head and do anything about it is again, a bit of a serious choice.
This makes me think what if we could find nylon gaskets that are the same size as G1 tail washers? I would use those... After that conversation the other day about nylon zipties being OK with ponies because after all the hair is nylon.