Hi Flav -

When my 1997 965 needed rear pads, we were away from home and the noise was real bad, so we hit the nearest Brake Check. The pads put in were the lowest cost from AutoZone since Brake Check had none in stock and we were stuck.

Had a first and good look at the rear brakes and general underside of the 965. The thinness of the rear rotors was amazing to me. Looked like about half as thick as the 240's. My newest 240 is the 1988 that you saw, and it has the old familiar Volvo multi-piston caliper set-up.

I wonder if the single piston floating caliper system (is that what's on your 1993 240 because of ABS?) is subject to vagaries that the old system is not?

Your symptoms sound like the inner pad and outer pad are not perfectly parallel, which would account for the cupping, if I understand you correctly.
I dunno what could cause that, or if it is something that happens after the caliper is manufactured or something that can happen later.

Good Luck on your trip and with your singing.

Regards,

Bob

:>)