I know I will have to drill out rivets, but I don't have an industrial strength rivet tool. Can I replace the rivets with screws? Any suggestions how and what size to use?

1993 940 Left Front
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I'm stuck on Volvo and Volvo's stuck on me....

Why do you think there are rivets involved? I have removed a few Volvo 240 and 700 regulators, installed a few, but have not encountered a single rivet.

The 940 and 960 regulators are riveted into the door panel, and the notes I've read are to use rivets when you replace them. I only have a light duty pop rivel gun and I don't think it can handle the job, so I'm wondering (with as common as this repair is) if someone has used regular hardware.

I think Rule708 even wrote something about using a rivet tool that ran off a compressor. These steel rivets must be really tough.
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I'm stuck on Volvo and Volvo's stuck on me....

I've never 'Mounted' a Regulator before ( good luck with that sex fetish). : )

Not on a Volvo specific but I have replaced Window Regulators before. I used 1/4" hardware. I used internay Star washers on teh Nut side, They bite into the metal so they wont back off. Careful of the length of the bolt, don't want to crash into the window.
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'75 Jeep CJ5 345Hp ChevyPwrd, two motorcycles, '85 Pickup: The '89 Volvo is the newest vehicle I own. it wasn't Volvos safety , it was Longevity that sold me http://home.no.net/ebrox/Tony's%20cars.htm

I haven't looked in there before, but I can't see why you couldn't use screws. Probably stronger than a rivet. Perhaps a lock washer or some lock-tight to keep it from shaking loose.

Just zip the heads off of the old rivets, and tap out the body and bring it to a hardware store find a screw "close enough" width-wise and as short as possible. You might have to cut the screws if there are clearance issues.

Good luck,
-Ryan
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Athens, Ohio
1987 245 DL 312k (Dog-mobile)
1990 245 DL 133k M47, E-codes
1991 745 GL 290k (Girlfriend-mobile)
Buckeye Volvo Club