I got a westin sportsmen grille guard in sept 2001 and when I was checking it over today I noticed the removeable headlight covers are rusting, not just surface rust but pitting. the rest of the unit seems fine just that area is bad.
The unit has a five year warranty on finish but I don't want to have to take off the old one, get the parts store to order a new one, then reinstall every year.

Anyone have similar problems or a solution.

Here's a solution: HERCULINE IT! :hammer:

My westin sportsman brush guard is doing the same thing. Especially around the knobs for the headlight covers. I totally forgot about the warranty though. I guess I will have to look into that. Do you know what it covers?

The warranty is for 5 years on the finish, what you have to do is remove the unit, take it to where you got it with the sales receipt and they will get you a new one.
I emailed Westin about just getting just new headlight covers and if the rest starts to rust then removing and returning the whole thing. Haven't heard back yet.