Rust below tailgate behind rear bumper - repair panel?

[Stephen Edwin]

I'm about to get the rear end of the 240 looked at. It is clearly visible looking up behind the rear bumper in the usual area. I'll get it done. There's a body work chap who has done work for me before and that work is still OK.

I recall mention in the forum of repair panels being available. Someone said they went to a repair bodyshop and supplied the panel which was gratefully received as useful.

What is the current recommendation and experience about getting that repair panel please? Who sells them and is there a realistic choice between suppliers please?



This 240 is getting a few jobs done...my health must be improving if I'm getting things done.

And an MOT is booked for 8am Wednesday, a month less one day before it is due. A different place a different tester. I suspect the previous place might not have been rigorous and that's no good. This tester is fully happy to show me what he is inspecting and finding as he does the test. And to have an additional look at the bodywork underneath before I go to the entirely separate bodyshop.
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[Derek UK]

I think Braydons was mentioned and the price was just under £90. Goes all across and a bit up the sides. Picture of this panel wanted. Mine could do with replacing too. If you ask them please ask them how many of them they have in stock. Ta.

[Stephen Edwin]

Thank you.

Brookhouse seem to do two slam panels, one repro B9025670 and one genuine Volvo 3528946. https://classicvolvoparts.co.uk/part..._Repair_Panels

Are those, one of them, what I am likely to need? I somehow imagined something extending down the bodywork a bit but I don't know why I thought that.

Edit: 'phoned FRF Volvo. They have quoted me £72 including VAT and after discount. Delivery cost wiould be determined by size to be measured when they receive it. Probably about a month from Sweden. Volvo Classic Parts.

Brookhouse web site says £82.20 for the Volvo part. If I remember Brookhouse pricing correctlythat would be plus VAT. And they wuld also have to charge delivery.


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[Stephen Edwin]

Well. The body shop man is of the old school and will bend his own metal. He knows a bit about Volvo. Has done a rather nice 144.

The quote to cut out &c. &c. &c, and to re-spray the metal sunshine roof and fix two small rear wing patches is a bearable price. He is a sleeves rolled up sort of chap. Gets stuck in looking at the car before giving his opinion and price. And his previous work for me is lasting. So I ain't shopping around.

It's good to have a car with signs of a decent length of future and so it is worth paying to get done.

And as of this morning the MOT is valid until 29 September 2018 and no advisories .

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[Jungle_Jim]

Here's a useful discussion about this, including a pic of the replacement panel...

https://www.volvoforums.org.uk/showt...e+repair+panel

Stephen - I'm not saying your repairman isn't very good - but I would suggest using the replacement panel. Making a 240 tailgate fit is hard at the best of times, but making the tailgate fit with a hand-fabricated sill beneath it sounds like a nightmare. It's a deceptively complex curve with a shoulder that the chrome trim goes on.

My two-bobs-worth,
John

[Stephen Edwin]

Ah good. That 2014 thread. Thank you. That is useful information.

That is perhaps summarised by Mike Brace. To misquote Mike, different cars need different areas and amounts of metal - one finds out when one actually does the job, And other people posted similar comments from their experience.

My repairman has carefully inspected the car. And his plan and price take account of whatever might be there when fully opened up. A gentleman of the old school.

The two photographs of the panel are very helpful. Especially compared to the info available elsewhere online. They do very usefully make it seem clear that the panel extends down to or towards the floor pan. That panel might even include part of the floor pan. That is information I did not have for my repairman and I will pass than on.

And that part (same number anyway, 3528946) is still supplied by Volvo, via both Brookhouse and Volvo dealers. Cheaper from FRF Volvo. It's from Volvo Classic Parts, has to be ordered from Sweden. Unless Brookhouse or someone has some in stock.

[simplysimonroberts]

Just thought I'd let you folks know of what can lie beneath these rear panels!
A bit scary. I ordered the original top panel part from Simon Richardson at Brookhouse (very helpful chap) and it arrived here, in Auckland, within a few days. I'd suggest choosing the original panel over the copy for sure. However, when my panel beater (as they're called 'down under!') drilled out the spot welds and removed the top panel, the second and third panels underneath were stuffed. No wonder this was the water / rust trap that it was.
The first three photos show the original top panel in place. Doesn't look too bad does it?!
The fourth and fifth photos show you what was underneath and if you look closely you can see where panel two and three (the floorpan) 'meet.' You can also see the new top panel part sitting waiting to be patched in. It's going to have to wait a little longer damn it!
So I've just reached out to Simon again to see if indeed the 'second' panel is available. You would need to be a very skilled metal worker to create the top panel and somewhat so the second. The third is basically the rear lip of the floorpan and is a more straightforward repair. So I'm keeping my fingers crossed the second panel is available and here are some pictures for reference:

[Stephen Edwin]

Hello Simply Simon Roberts
I am Stephen Edwin Roberts.

Edwin being my late father's name taken by me at confirmation.

Anyways. I have at last found a welder bodyshop panel beater in range of home and taking the concept of this job seriously. I will take print outs of your photographs to him thank you very much. That panel you have is the panel I have got, bought from FRF Volvo dealers.

Thanks again.

[Stephen Edwin]

Those photos are truly excellent. Thank you again. And however I can't really get my head around the full nature of the structure yet. I'm taking those photos to my newly found welder tomorrow. I hope he can explain to me.

I think the garage trade including annual MOT testers don't understand. A tester failed my car on that rust this morning. (I think a second opinion tester will pass it tomorrow morning, that's a different matter see below.) But. The tester who failed it, looked up under the bumper and said get a welder to weld a plate on it....I tried to explain that it is known to go deeper but he wasn't listening.

Second opinion tester says NOT anywhere near a point that is subject to MOT rust test. He does agree it must be repaired, and it is in process of being booked in to a welder.



P.S. It seems the repair panel is available because: that panel although not the actual problem has to be replaced to do the job, and it is especially difficult for a welder to make that panel. Is that a fair assessment of that aspect?

Hey ho.


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[Stephen Edwin]

Originally Posted by Stephen Edwin

P.S. It seems the repair panel is available because: that panel although not the actual problem has to be replaced to do the job, and it is especially difficult for a welder to make that panel. Is that a fair assessment of that aspect?

Hey ho.


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Well the bodyshop say for my car it is just possible they could cut out and deal with only the rusted area, leaving the original complicated shaped panel in situ. But most likely to cut back to sound metal they will need to use the repair panel.

They are a, do not pre judge what we will find body shop.

For the actual problem area, they propose a number of pieces be welded in, fabricating new panels would be seriously more money. I'm not a purist. A sound repair done to last is good to go for me.

Has anyone found panels 2 or 3 available? Please?

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