I have some rust issues in the rear end of my 1987 Volvo 240. When I lifted the carpet in the third seat compartment there was a good handful of rust scale under there. It came from the area under the tailgate and above the bumper. I can hear “outside” back there when I am driving, and I am concerned with exahaust possibly entering the car. I know this is a common area for rust, so I am hoping there is some wisdom on repairing it. I do not weld, and I am looking to fix, not restore it.

I don't know what part of the world you hail from but I had the same problem and due to concerns over carbon monoxide I effected an immediate 'bodge' with fibre glass to keep me going. I then promplty forgot all about it. My car then subsuquently passed its (UK) m.o.t. without any problems, the tester claiming it is not structural and therefore not an m.o.t. concern. I have since had it welded and retrimmed the inside with new carpet to hide the repair. You could try rivetting some plate in there I suppose but whatever you do, do it NOW cause CO poisoning is not nice. No siree.

Dear Knut,

Look for a product called EXTEND in liquid or aerosol. Clean the area with a steel brush and apply. This stuff stops the rust and hardens it. You can use a fiberglass paste over a mesh patch. I repaired a floor panel by using a square piece of sheet metal attached with sheet metal screws.I attached it to the underside and filed the screw tips flat on the inside.Then I sprayed the area with several thick coats of undercoat.

Goodluck

Mark H.

Dear Knut, We all have it. I use POR-15 from IPD or Eastwood or other sites. Then epoxy and fiberglas cloth about 4-5 coats and its as good as new ? Well the exhaust doesn't come in at least. You could also cut and weld a piece in or cut and screw in a new piece after POR -15 ( or other rust converter ) use and then seal and paint. It shouldn't take more than a few days. If it is bad welds can be done by local shops. This makes it alot stronger. Then use the POR-15 on the new metal and the sealers/ epoxies and paint.

2 245's, 3 745's(2 turbo's)