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Yep, BTDT several times. The easiest repair is to toss in a complete strut assembly from a wrecked donor.
You can buy new spring cups from the dealer -- they're galvanized -- and MIG weld them on the tube, but I suspect that costs more (for the labor) than a used strut.
In fact, when I junk a 240, I keep the struts if the cups are solid.
Incidentally, it's less common on the '86 and newer 240s because Volvo went to galvanized cups around then. The older 240s used to eat those things up (at least around here).
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Don Foster (near Cape Cod, MA)
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