Reply to "Headlight bucket rust"

MB, I doubt that the headlight buckets you've seen are perfect. The rust inside the bucket is common, especially on the bottom since 1) there are no drain holes and 2) quality of corrosion control on inside surfaces from the factory is iffy at best. Is the "worse case of rust" all the way through? If not, as an interim measure, you could use POR 15 or a similar rust encapsulation product to slow the process. This may provide enough time for you to find a suitable replacement prior to repaint. You will see them on e-bay occasionally. I think fabrication would be pricey.