Purchased 2007 Toyota Rav4 for my son. The inspection failed due to rust rot under the driver side Rocker Panel. I'm assuming this isn't structural. If the concern is just about engine fumes/gases not entering the cab, can I just do a repair with some Great Stuff foam and Bondo to fill the holes?
I don't know if it's structural on that vehicle but I do know that if you use foam and fiberglass it still may not pass inspection, depending on what the inspectors are looking for, and will continue to quickly rot out. It would be a very temporary patch job at best. The only real cure is to cut out the rusted metal parts and weld in good replacements. (If it's not structural you might be able to get away with pop-riveting replacement metal in place and sealing it. However fiberglass and foam will trap moisture and just make the problem worse.)
on unibody vehicles, seams like the ones under the rockers panels are structural and stiffen the vehicle. In a crash it could buckle and crush the legs of the occupants.
