How bad is it for a tube power transformer to be showing signs of rust?

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External rust is NOT a problem.

Violent rust removal, such as a power wire-brush, can do harm.
 
For light surface rust I use Scotch Brite pads sprayed with a little WD-40 (don't use steel wool!).  Scrub it and wipe it clean, then hit it with a rag wet with acetone to remove the oil before re-painting.

I have also seen transformers covered in rust that continue to work fine for years...
 
I have one that looks like it came off the titanic that works great.  There is a debate about the validity of having rust included as part of the design; I can't speak in any knowledgable way about it, but have heard it.  It sounds too voodoo for most people to consider, but had solid reasoning behind it. 
 
Hi Doug,

Thought I read that too:

http://www.mercurymagnetics.com/pages/news/VGmag/VGAug09Hamernik.pdf
 
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