V70 Cargo Cover/Tonneau Cover Repair

Volvo Forum member Rob3 posted a tutorial on his ingenious V70 cargo cover repair.

tessiev70 »

I recently purchased a 2000 v70 GLT and everything about the car is perfect with the exception that the cargo cover in the trunk area is overextended and will not retract.

Rob3 »

Well, I fixed mine. Warning! After this fix, it is very difficult (but not impossible) to remove from the car. It will cause the inside of the Cargo Cover Assembly to be 1/2″ longer than it was originally.

I used 1/4″, 3/8″ & 5/8″ Copper Tubing for the fix. I’ve attached some Pictures.

I first filed a Slot across the ends of two 3/8″ x 6″ pieces of Copper Tubing. (The extra length is to make them easy to handle.) The depth of the Slot is not critical. I made mine about 1″. (See Coupler 1.)
Then I cut them 1/4″ longer than the slot. (See Coupler 2.)
Next, I notched the opposite end at 90° to the Slots. I used a 5/16″ Drill Bit Shank to help hold the slotted end while making the Notches. I made the Notches reach to the end of the Slots using a Rat Tail File. (See Notched 1 & 2.)
I laid a piece of 1/4″ Copper Tubing into the Broken End Caps and marked the center of the Broken Portion with a Sharpie. (See EndCap and Notched 2.)
I used a File to make the Mark permanent, so that I could sand the Copper Tubing without losing the Mark. I sanded the Copper so that the Solder would “stick”. I positioned the Mark over the center of the 3/8″ Couplers and gently tapped them with a Hammer. I used pliers to slightly squeeze the coupler over the 1/4″ Tubing. Then I soldered them together. (See Soldered.)

[there’s much more, click link to for the rest]

Tonneau Cover Repair:
Rob’s V70 Cargo Cover Repair