Dear sd___,

Hope you're well and stay so. Were you able to patch the hole?

If so, what materials/methods worked?

Yours faithfully,

Spook

If you can't source a good used tank then there are options for repair. There are a number of epoxies available specifically rated for fuel tanks. Lots of YouTube videos on such repairs. For repairs of longer cracks and larger damaged areas you may want to consider plastic welding. There's a feature article on this here in the 700/900 FAQ describing a DIY method
https://www.brickboard.com/FAQ/700-900/FuelTankRepair.htm

Be sure to work safely and perhaps go a bit overboard making a solid repair. I'll add one thought, when repairing cracks in plastic, drill a hole at the very far ends of the crack to act as a stress relief point so that the crack won't spread further. Looks don't count here, although a tidy repair and perhaps a protective layer of undercoating will help keep mechanics from raising their eyebrows when the vehicle is up on a hoist.
--
Dave -still with 940's, prev 740/240/140/120 You'd think I'd have learned by now

Dear sc____,

Hope you're well. Yes. According to Volvo VADIS - a superseded dealer parts/service database - and the Volvo pocket data booklet - Cars (700, 900, S90, V90, 850, etc.; 1991-1998] you need Part #9140688.

This 80-litre tank was used in Volvo 960 Sedans (1992-1998) and 960/V90 wagons (1995-1998). Other models/years of 960s used tanks with a 75-liter capacity.

A fuel tank from a 940 will NOT fit. The rear suspension of 940s differs from that of 960s & S/V90s, so there's no fuel tank interchangeability between 940s and 960s.

I suspect few salvage yards keep fuel tanks. They rarely fail: the plastic tank walls are about 1/4" (6.5mm) thick. As the tanks are emplaced out of harm's way, only a road hazard (sharp piece of metal) is ikely to reach a tank.

Most salvage yards' inventories are networked, so one salvage yard can locate a part in another year, even if it is 1,000 miles distant.

Shipping on a fuel tank will be expensive as they're large, albeit not especially heavy.

Hope this helps.

Yours faithfully,

Spook