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Fixing rocker panel rust - 99 s70

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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Re: Fixing rocker panel rust - 99 s70

Post by volvolugnut » Tue May 19, 2020 5:21 pm

I would seriously reconsider any panel source that had to be cut with a hacksaw. Sheet metal cuts easily with a jig saw (sawsall would also be a good choice). Blades get in a bind and break so take plenty of spares. You will have to cut several layers so the long blade sawsall may be better. Key is to keep down pressure so the saw remains in contract and the saw cuts on the pull stroke. It can get loud.
2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

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Re: Fixing rocker panel rust - 99 s70

Post by abscate » Tue May 19, 2020 8:02 pm

Yeah, after looking at the steel in these cars, hacksaw cutting isn’t happening.
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