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If your PCV valve is rusted something is wrong, or maybe that's just a problem with you continental guys. I don't understand how rust gets all over your engine. You might be ok just getting a new valve and taking it to a shop and just tell them to change it (and only that). Either your oil problem will be done, or it will persist and gum up your new valve. Even with it stuck open I don't think you should be getting globs of oil coming out of there. Are you driving up steep grades?
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I didn't see the part where you said you'd take the mani off. That's good, too.
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