Pennsylvania drivers must have their vehicles inspected annually to ensure that all drivers maintain their vehicles correctly. Inspections look at many aspects of a vehicle, including areas of rust, to ensure that the vehicle is safe to drive.
While a vehicle's body and floor pan are inspected for rust, the Pennsylvania Department of Transportation does not have a set size at which a vehicle will be rejected for having a rust hole.
Regardless of hole size, vehicles that present at an inspection station with a rust hole in the floor pan that presents a hazard to the vehicle occupants or allows exhaust gases to enter the passenger areas of the vehicle will not pass the inspection.
Though the Pennsylvania Department of Transportation makes no specific mention of rust holes on a vehicle's body, aside from the floor pan, inspection regulations require that there is no torn metal protruding from the vehicle. In certain instances, rust holes may result in torn metal and a vehicle rejection.