srgtlord:
Alright well I guesse Ill just drive it until it crumbles
Amen to that!
I had one car that rusted the rear wheelwells so bad that if I drove it in the rain, water would splash up inside the rear quarter windows. At that point I admitted it was time to retire it.
As far as the question about structural integrity/ crash safety.... you would have reduced crash protection far sooner than noticeable issues with structural integrity. How much rust would it take to lose 20% of the sheetmetal thickness?
Some signs it's too far gone (and all have happened to me):
1. You jack up the car, and the jack goes up but the car doesn't move off the ground.
2. You can take a large screwdriver and hold it against the subframe, and then push it right through the subframe.
3. The aforementioned water splashing on the inside of vehicle glass while driving.
4. You hook up a tow rope to the bumper supports and the entire bumper assembly and supports pull off the frame.
5. You try to jack up the car and can see the subframe compressing as you put weight on it.
6. You pull up the carpet to check the floorboard condition, and there is no floorboard - you are looking at the top of the gas tank.
7. You are trying to do some weld repair, and can't grind back to good metal that is thick enough to weld without burning through.
8. If you jack up the car with the doors open, you can't close the door.