Before fabbing something up or buying something new, how about looking in a salvage yard?
The part you're looking for is the flat intake piece, from the front grill to the side of the air box, right?
Or if you can't find one near your or don't want to deal with searching yourself, these options may work. Both are salvage yards who serve a lot of volvos. I personally have never dealt with either, but have read of a TON of people on other volvo forums who highly respect both of these outfits. I am not affiliated in any way with either.
http://www.erievovo.com/
http://www.vandsautodismantlers.com/
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'86 245, 188k, '00 V70 98k
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