I think you're going to have to give a better explanation than that, and perhaps include a picture or two.
..

 

Are you talking about this thing? If so, good luck. And that is some real horse***** that PA won't pass it. About every car back there has rust issues.

 

This is beginning to become common...just in the last 5 years or so lol.

Guess you could have a yard torch one off, have it welded on. If it's just the bottom, there might be enough metal left on the sides to patch it...

Make sure you leave a good size drain hole in the bottom, so it doesn't plug with foreign matter lol.

 

Right.. keep the foreigners out.

 

 

 

Weird how they rust differently. That first pic was my Expedition. This one is my F150. Most of its rust is on the side of the stop, rather than the bottom - like my Expy.

 

I've often wondered if I could make it stop if I put expanding foam in it.... but that would most likley just relocate the rust area, lol.

 

I guess I should have realized that this was the component being addressed. My bad.

I'm surprised that this piece would be an inspection point, but then again, I think that most *any* body rust is cause for rejection in PA, if I recall correctly. I seem to remember a lot of auction cars coming from PA to Ohio for that reason.

I wonder what the stops on my '99 looked like. I don't think I ever looked. As for a fix, yeah, that does look like a conundrum. Fill it with foam, bondo it, and shoot it with some flat black for the inspection, maybe?
..

(Note: The author of this post in no way condones misleading vehicle inspectors, or in any other way circumventing proper procedures for the state of Pennsylvania or any other governing body.)