Will rust fail my safety inspection?
It depends entirely on where the rust is, and this is the single most misunderstood part of the inspection. The standard states outright that some rust and corrosion on the outer surface of exposed metal parts is normal, and that minor surface rust is not cause for rejection. Cosmetic rust on a door skin, fender or quarter panel does not fail a vehicle. What fails is corrosion that perforates or structurally weakens a structural component.
Which parts of the car count as structural?
The standard includes a list, drawn from Regulation 376/02. It covers the radiator support assembly, upper and lower rail assemblies, front strut tower and apron assemblies, cowl top panel, engine sub-frame, dash panel, the A, B and C pillar assemblies, side rocker panel assemblies, front and rear floor pan assemblies, structural roof panel, rear strut tower and inner wheelhouse assemblies, inner quarter panels, rear cross-member, upper and lower rear end panels, rear sub-frame assemblies, trunk floor pan, and on a body-on-frame vehicle the complete frame assembly. Rust perforation on any of those fails the vehicle.
Can a rusted floor be patched to pass a safety?
Within strict limits, yes. Repair of corrosion holes in the vehicle floor is permitted provided the hole does not extend into a structural area of the floor such as seat belt anchors, seat supports or rocker panels. The prepared edges of the hole must not exceed 200 mm in length, and must not extend within 50 mm of the tunnel, rocker, seat support structure or firewall. Pop rivets are not acceptable, and neither is arc welding or flame repair on high-strength steel, nor TIG or MIG stitch welding.
Why do so many Ottawa cars fail on rust?
Road salt. Ottawa runs a long, heavily salted winter, and salt spray attacks exactly the areas the standard treats as structural: rocker panels, the bottoms of the pillars, floor pans, strut towers and frame rails. A car that has spent ten winters here can look perfectly good from three metres away and still have a rocker panel you can push a screwdriver through. This is why an out-of-province vehicle from a dry climate often sails through a safety while a local car of the same age and mileage does not.
Does a rusty exhaust fail a safety inspection?
Surface rust on an exhaust does not fail it, but the standard fails a manifold that is broken, cracked, leaking, loose or missing; a muffler that is cracked, perforated or leaking, or that has been bypassed, disabled, removed, or patched in a way inconsistent with industry standard; and a resonator, catalytic converter, particulate trap or exhaust pipe that is cracked, perforated or leaking. Usefully, the standard notes that minor leaking and the resulting soot tracks at exhaust joints are normal. Any exhaust component that causes gases to enter the occupant compartment fails outright.
Do body damage and dents fail a safety?
Not for being unsightly. What fails is body damage that creates a hazard or a structural problem: a section with an exposed sharp edge, torn metal, or a part protruding in a way that could injure a driver, passenger, pedestrian or cyclist; body components loosened by broken welds, missing fasteners or failed adhesives; and holes in the floor or panels that allow water splash or exhaust into the occupant compartment. Missing or badly corroded fenders fail if road spray is no longer controlled.