wow, that sucks man. i've only had one issue w/ my ABC stuff: there was a small warp on my rear bumper, but i think that came from having stuff sit on top of the box for the 3 months it sat in the garage. other than that, i really have no complaints w/ the quality. it's actually held up VERY nice to the abuse i've put it through (hit a curb while out of town--bumpers and side skirt cracked, but were repairable).
i tried getting them to send me another, but the guy (who was an @$$ on the phone) pulled the same thing--"past the 30 days"... wonder why he told you about a year warranty.. that's pretty shady.
anyhow, i really can't complain... sorry about your situation, man. since it's that bad, i would actually consider pursuing legal action. then again, it may be cheaper (and less trouble) to just order another rear bumper... probably from another company, too.
good luck.