>I am interested in replacing the lumbar support on my fiend's `81 240.

The only thing that I would add would be in reference to the back cushion. If the lumbar support has been broken for a while it allows the seat back cushion to break down rather quickly. Volvo changed the design of the seat back in 1986 (or there abouts). 86 and later has a tube running down the outside edge of the seat back frame and over time they push through the foam cushion and make the seat loopsided, ugly and uncomfortable. The only way I've found to fix them is to get a new/used cushion from one of the recyling yards. Prior to 86, however the cushion doesn't loose its shape so much as it just starts to break up into large chunks (mostly around the lumbar support). I have had great success in fixing that problem by inserting a carpet sample between the lumbar support and the cushion. The ones I use are thin (very short pile) stiff samples that measure 13 1/2 x 18 inches. I get them at the carpet store for a quarter. Make the repair to the lumbar support and if you haven't already you'll need to cut the ring that holds the support to the cushion and slip the carpet sample in. It is a perfect fit and doesn't need anything but the lumbar support to hold it in place.

BTW if you form your own replacement wire for the support be careful to get them as close to the original length as possible to have the same range of adjustment in your "new seat". While you have the seat out it might be a good time to check the bottom suspension too. The two forward most springs have a tendency to slip off of the wire rail attached to the bottom cushion. It's a poor design that can be corrected by bending the end of the wire rails out to prevent the spring from slipping off again.