This is a 2-part posting relating to my '87 240 wagon. My floorpan (both sides) is shot. It's fix it or send it to the crusher. It's an otherwise good car.

1. What caused it? All of the 240s in my local junkyard, about a dozen, all ages, have no visible floorpan problems. I am gearing up to attempt a floorpan replacement on it, so today I took out the front passenger and rear seat and pulled back the carpet and foam underneath. Here's what I found. Aside from the rusted pan, the front carpet was damp. On closer inspection, I noticed leaves in an area below the heat exchanger behind the dash. A lot of leaves ... I pulled out several handfuls from both passenger and driver's side. What gives? It's obvious that if leaves can get in there, so can water! This has got to be remedied before I can begin to think about the floorpan.

2. If the dash or firewall leak can be fixed, I would like some advice on the floorpan rebuild. I've heard it's best to cut out and weld a section at a time to maintain the structural integrity of the car. The Volvo, however, has a one-piece structure that spans the width of the car that both seats are attached to. It is spot-welded to the inner rails and the floorpan and is above the floorpan. When I remove this piece (which is in pretty good shape) to get at the floorpan, does anyone have opinions as to any problems that might arise? Should the car be supported in a particular way? I see no feasible way to start and complete one side first without removing this entire part first. Thanks!