I backed into my camper in the driveway at about 3 mph. Hardly scratched the camper, but the bumper fell off the volvo. Seems the metal inside the bumper had was suffering from severe corrosion where it was bolted to the car. Any clues as to how I can repair it?

Mark

Problem is a galvanic corrosion caused by 2 disimiliar metals contacting each other. ( aluminium and steel ) I've searched pick and pulls for a good bumper but they all suffer from the same problem corrosion problem. I repaired/reinforced both rear bumpers on my 2 1990'2 and have been happy with the results. In both cases I used 4' x 1"" x 1/4"" steel stock purchased at Lowe's. Also used the sandwhich method mentioned already. I painted both the aluminium bumper and steel stock with POR 15 to try to isolate the metals.

I understand how the sandwich method works, but how did you do the non-sandwich repair?

I bolted the steel bar on the outside of the bumper in about 4 spots that didn't have any of the stress cracks or chunks missing also drilled 4 holes to line up to the bumper mount holes. So basically the steel is bolted to the bumper and the bumper mounts to the steel. On the top only one of the 2 bolt holes was use. I just moved this one bolt to the opposite hole and drilled a new hole in the bumper.

Thanks.

Two more questions:

1. What did you do about the plastic tabs which protrude from the bumper cover through the aluminum. Are the clips supposed to remaim attached to the aluminum? All of mine came loose and split into two parts (looks like a rivet failed).

2. When you drilled the holes for the mounting bolts how did you line them up with the holes on the bumper shocks?

Mark

It's a chronic problem on Volvos around eastern Canada where, between salt in the air & salt on the roads, aluminum doesn't stand a chance. In the absence of a good used bumper, you can make do by cutting strips of steel plate to place between the bumper & the cover, and drill holes in the steel to line up with the bumper mounts. Bolt it all together to make a bumper sandwich. Reinstall the cover (you may need to do some 'adjustment' to the plates with a grinder) and voila - a reasonably effective repair. Be forewarned though, this is not going to be a permanent fix and the bumper will not have its previous strength so you are sacrificing some of the safety of the vehicle - but it'll still be much better than what you had before. Ideal fix is, as previous post mentioned, a good used one sans corrosion.
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Chris, Dartmouth NS Canada 70 M-B 280SE, 83 245DL, 84 244 turbo, 90 780 turbo, 92 VW Golf, 90 740 Rex/Regina

Pull another at a pick and pull. '86 and newer needed if you are doing a front bumper, but I am not sure if the rear changed that year. I believe wagon and sedan bumpers are the same.