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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.
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abscate
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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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Re: Fixing rocker panel rust - 99 s70

Post by smacknab » Thu Jun 25, 2020 4:18 pm

Found some new rust by the cat, under some insulation. Super crusty, right where some weld happened, looks like where the firewall and the body meet.

Anyway this is making me reconsider my plan, because I'm not sure how to fix this correctly. Or if can be because of the weld.

Thinking about swapping the maual and all the new parts, maybe the engine, into a 99 wagon.
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99 s70 NA m56 - >215k miles

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Re: Fixing rocker panel rust - 99 s70

Post by abscate » Thu Jun 25, 2020 7:28 pm

Meh, it’s some frame rust. The car has a good 5 years left or more , without repair.

Evan might have a 99 wagon for a swap....

:D
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Re: Fixing rocker panel rust - 99 s70

Post by smacknab » Fri Jun 26, 2020 8:28 am

I can poke the passenger side floor board foam haha seems to be water seeping out there, not sure where from. Doesn't smell like coolant and it hasn't rained in awhile maybe the exhaust bolt just rusted out and started this.. who knows..

Anyway do these photos make it look much worse, or about the same?
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99 s70 NA m56 - >215k miles

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Re: Fixing rocker panel rust - 99 s70

Post by Sveedy » Fri Jun 26, 2020 9:05 am

It's beginning to look more and more like a " Katrina " car, or the equivalent. Just not normal, IMHO.
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Re: Fixing rocker panel rust - 99 s70

Post by smacknab » Fri Jun 26, 2020 9:13 am

Sveedy wrote:
Fri Jun 26, 2020 9:05 am
It's beginning to look more and more like a " Katrina " car, or the equivalent. Just not normal, IMHO.
Totally fair, I spoke too soon with my 'rocker panel is the only rust spot' thought comment. I might take your advice about finding a good body, my buddy said he would help so I'm sure we could knock it out in a weekend or so. Should I stick to a 99 body? Or would any 99-2000 cover most of my parts? I'd probably swap in the engine and trans together, all the new hoses, the new engine mounts, the full suspension, brakes and the AC system etc.

That said I'm buying a house right now so I might have to ride this car out for awhile.

Any thoughts on mitigation I could do in the meantime? My buddy suggested sanding it out and we can rivet in a panel and seal it. I have a can of por-15 as well.
99 s70 NA m56 - >215k miles

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Re: Fixing rocker panel rust - 99 s70

Post by Sveedy » Fri Jun 26, 2020 1:48 pm

Well others on here know way more about compatibility than I do. For some reason I thought '99 was a transition year of sorts, but I would think that '99 - '00 would be a safe bet. Probably comes down to how much you need to switch over the further you move from your year. I think one member on here (bmdubya1198 ? ) could probably switch out your drive train on his lunch hour from what I've seen :)
I would just drive it as is and not put any more energy into it till you have your donor car. House is WAY more important - Congratulations !
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Re: Fixing rocker panel rust - 99 s70

Post by abscate » Fri Jun 26, 2020 8:09 pm

You need to patch that so that if you get an exhaust leak, it doesn’t end up in the car.
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Re: Fixing rocker panel rust - 99 s70

Post by smacknab » Fri Jun 26, 2020 8:17 pm

I've decided that I'm now piping in exhaust sounds like the modern cars, so I think it qualifies as an upgrade. It's all about perspective right?
99 s70 NA m56 - >215k miles

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