Welding it will most likely be a temporary repair. Getting it clean enough for a good weld is going to be the problem.

Hi, My 97 850 GLT has developed a break where the pipe to the muffler attaches to the cat. The shop I've taken it to says they'll have to replace the cat to repair it because they can't weld it back together (partially because there's too much rust, partially because they don't have a welder with a...

Take the car to a shop that know how to use a welder. It's easy and not more than 10-15 min repair. This is what I've done with four P80 cars, all of which broke at that spot in the exhaust. Take it to the local exhaust shop (not the chain, the local shop) and have them repair it in place. Repairs ...

I live in a ice cold state, it's likely condensation in the fuel system. Next time try a bottle of HEET. I have been using this inexpensive product for 30 years with great success.

Also keep the fuel tank full in the winter to reduce condensation. Especially when it gets below 25 F.

Volvo of Toronto online store is often competitive and offers free shipping on orders above $ 150 I recall. They are pleasant to deal with and helpful on the phone and appreciate if you look up your own part number.

If it were me - hit it with a needle scaler, some rust converter, self etching primer and then some paint.

The rockers can get corroded on the back side as well. Check especially at the rear of the rockers in the area of the rear axle mounts. They can get really crusty there.

Neil.

1. Is there any other rust related damage known to you-subframe, strut areas, badly rusted brake and fuel lines. 2. How much work are you able/willing to invest Into it in case you will decide to do it yourself(can you live without a car for 2 weeks, cost of repair related materials, your labor(time...

On the bright side, the more these cars rust, the less they weigh and generally the better the fuel economy will become =P

can invest a fair amount of time, but I have no experience with body work so I'll be learning as I go. My husband will be helping and the cats can look after themselves for short periods of time.

Idle cats are the Devils minions….