How common is this?

[boxman]

The rubber topped mat that is underneath the carpet hides too many problems - how many of us have pulled up the carpet, felt underneath and all seems dry, so assumed that there was no water in the footwell- only to pull up the rubber layer underneath to find a sodden fibre matting under that?

I did and was horrified - thankfully mine was only water getting through the firewall past the bonnet pull grommet so a good dry out sorted it. But I reckon it was wet for years before I found it.
I would recommend all volvo owners check under the rubber mat and sort the problem before long term damage strikes !

[RealEstate]

Originally Posted by Chris740R

So to the people that have had repairs done, was the hole patched or was a new section welded in?

On my '91 940, the hole was ~1" wide x 4" long beside the longitudinal box running backwards under the pass floor. The garage welded on a narrow plate patch on the underneath - I think there is a brake pipe running along there, which they had to work round. Easy to do, cost £90.
As Boxman says, it's good to check for dampness under the carpets as that's the culprit.

[Chris740R]

Well, I had some fun today.

It started out like this:
http://i98.photobucket.com/albums/l2...5062009269.jpg

Then, after peeling some loose underseal off, the words "hand me my hammer and screwdriver" were spoken, and this appeared...
http://i98.photobucket.com/albums/l2...6062009272.jpg

At this point I told the world what I thought of rust, and commenced attack:
http://i98.photobucket.com/albums/l2...6062009273.jpg

A repair piece was cut:
http://i98.photobucket.com/albums/l2...6062009275.jpg
http://i98.photobucket.com/albums/l2...6062009274.jpg

And here I hit a problem. I'm not a good welder by any standards and this stuff is paper thin so I burnt a couple of holes, and couldn't even get the two bits of metal to stick together. (This is using an arc welder). So work was halted at this point, tomorrows task is to find some one to weld it up for me.

[surrey_man]

Yuck i dont like stick am a MIG man my self

if your putting holes in it then theres a chance the current is set too high

[Chris740R]

yeah, I tried adjusting it, it just seemed to be crap no matter where the dial was set to lol.

I have a friend with a MIG that I might call on tomorrow.

[surrey_man]

i found mig gives a nicer cleaner weld

its a shame your up north and am all the way down here i would off offered my help

[Chris740R]

All welded up for the measly sum of £20

[Laney760]

Only just found this, glad you found it and got it nipped in the bud Chris. The floor of my 740 wasn't too clever whereas the rest of the motor was rock solid, always wondered if it was more than the fact it had been stood up for a year on grass. My Dad had to have his 240 floor welded too, which was a year newer than my 740...