> That said, rust on the front fenders ect., should not be reason to fail.

In my county the state police will pull the fresh inspection sticker clear off your windshield and threaten to take away the tech who put it there's license to inspect cars if they see "rough edges" due to rust holes along your tire wells (on the fender lip). They will similarly do the same if you have broken or missing cosmetic body parts (like the plastic that covers bumpers but serves no actual purpose besides looks & aerodynamics) leaving gaps or sharp edges, which they call "catch points" because in some absurd situations someone might, in theory but not in reality, get their clothes snagged on it and be pulled into the car if you hit a pedestrian.

PA really has two, no make that 3 different tiers on how hard or easy it is to pass vehicle inspections depending on where you live. If you're in an urban environment the safety tends to be lax but the emissions part is harder. If you're in a rural, especially if its poor county where emissions isn't even done the safety will be tough as nails. Some places are between the two extremes.