Brilliant - thank you very much - this might help cut down on the random threads I have been starting in this section!

The plan is - I will ask here instead

What to do about the grill?
 

This is one of those lucky : unlucky things. The outer part of the grill is in good condition but the insert is a mess.

https://www.volvoforums.org.uk/attac...1&d=1517854956

It looks like someone has already painted it in a silver grey

https://www.volvoforums.org.uk/attac...1&d=1517854956

What would you do?

1) Pay two hundred euros for a new stainless steel one
2) Spray it silver grey again
3) Try that gucci bling bling spray chrome in a can stuff...

Careful bead blast, spray dull or satin silver and you will be very close to original. Cheapest option.

Have you done this yourself? In which case perhaps you have a picture?

What was the original finish like - was it chrome?

No I've not done it but it has been documented a few times in various restorations. You could get it powder coated in satin silver grey at extra expense. No need for the job to be high on the list at the moment, there are more serious things to attend to.

When I got my 544 there was no paint at all on the grill, it was just rusty metal, so I wire brushed and sanded it off, then treated it with Jenolite, then gave it 2 coats of silver paint, and it looks fine.

It looks just right

Do you know if the grills were ever chromed?

Nope - not involving anyone else in the project - Dutch labour rates are not reasonable when I can do most things myself.

I have to think ahead a bit because I want to sand blast the grill on top other parts like the inner wings so I get the maximum effect of the sand shooting through those holes!

Then of course once that layer of rust is gone I need to think about protecting it before it needs to go back into the sand blasting cabinet (!)

Today got some holes filled in...
 

...in the front end panel.

Starting with a scrap piece of 1mm Zincor

https://www.volvoforums.org.uk/attac...1&d=1518017786

Bent it into shape

https://www.volvoforums.org.uk/attac...1&d=1518017786

TIG welded into place

(Make sure you clean off the galvanised layer from the Zincor before welding - fumes from that can kill ya deed)

https://www.volvoforums.org.uk/attac...1&d=1518017786

Turned out alright - it is a bit low so needs a bit of bashing wit ammer

https://www.volvoforums.org.uk/attac...1&d=1518017786

Moth eaten edge (shown in picture above) next then other side...

That's a good start. You'll make a car of it yet!