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> Has anyone had severe rust on new syncro rotors after=20
> say 2 years, or so, so bad that they are junk?=A0

Someone before asked the question of thickness, which combined how true the=
 rotor should indicate junk status or not. Very difficult to think that the=
re could be a manufacturing defect in the alloy, but you never know. Only w=
ay would be to install new ones, same pads and drive another 25k. Best gues=
s wiould be a poor quality pad since the pad should win over rust every tim=
e.

BTW- the rotors on my 99 Jetta form rust so quickly after driving you can p=
ractically see it happeneing. Makes a freaky scraping sound the first time =
you brake as the rust is removed. No problems, but I don't use my brakes mu=
ch so they are original at 110k. This is within blocks of the ocean which i=
s salt-central.

Pictures may help clarify the extent of rust that you're having.

john