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I think the rust part is stored in the alpha channel of the occ map. If I could manage to add the new texture as an alpha channel to this map, problem could be solved. But that alpha channel is made in a way that is beyond my understanding. Somehow its stored only a transparency layer of the original texture map and I have absolutely no clue how is this done.
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I believe that the rust is just showing in the occlusion texture, not alpha channel. You can paint it off, and we could probably use also SH 5 occlusion map (wonder what that would look like)? Yes, the alpha channel looks weird, but I think it's just adding effects to some areas, like details, pieces of metal that shine in the sun... The rust is showing simply because we use occlusion map with rust. And the rust won't show if we don't use occlusion map at all. If I would use occlusion map completely without rust (I haven't done this yet) there wouldn't be rust. I think rust is not the issue!
Of course I might be completely wrong too!
I could Zedi send my ship to you and see what you think of it, but I try to fix the small problem first.