Hello all, I have a 1986 240dl, body is in fantastic shape BUT I have some serious floorboard rust on both passenger and driver side. This in turn is causing weak center support. I just had a new clutch installed and this has given the car a big "shudder" in first gear, and when downshifting. According to my reputable Volvo mechanice, this is because old clutch was so weak and slippy, and now new super-strong clutch magnifies the shuddering problem intensely. My mechanic says rust needs to be cut away and new floorboard metal needs to be welded in and center support needs to be strengthened, then he will install new rubber driveshaft boot to eliminate/reduce shudder. He has given me the name of the body shop they recommend and calls this "typical 240 rust". I crawled under the car and it looked BAD to me, but it was just the floorboard areas, everything else looks really good.

Any ideas on what this is going to set me back? Is it worth the trouble? I have put alot of money into this car recently ($1000: alot of wiring redone, new valve cover gasket, new rear seal and clutch, new brakes, new right rear tailight assembly). I have not owned the car for very long and was not even aware that the car had underbody rust (stupid gullible female). But the body looks beautiful and the engine runs really well.

I guess my biggest concern is pouring MORE money into the car and fighting a forever battle with this underbody rust.

Thanks for the advice!