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It's been a while since I looked at a 240 with the headliner out, but I think there are 2 cross braces--between the B and C pillars, and maybe a third one over the cargo area. Sunroof cars are different from regular. The roof skin is only glued to the cross braces with mastic, NOT welded. If you can leave the two forward braces intact and open only the area over the cargo floor, I would not worry too much about compromising the structure, and some reinforcements of 1" or larger square tubing would make up for most of the loss---the braces are only ribbed strips of sheet metal, spot welded in place at the ends, that rely on the mastic holding them to the roof skin to make a crude approximation of a box section. My point here is that they don't really add all that much to the strength of the vehicle. I would much rather have a major crash in a 245 with a poptop grafted on (and a couple of crossbraces removed) than in a completely stock VW Bus.......
As for roof loading, it's either 50 or 80 kg (can't remember right off) for a roof rack and cargo. The top itself shouldn't weigh any more than that, and there will only be people up there is when the vehicle is stationary, at which time the weight is less of an issue. (too much weight on top affects stability while driving) The roof pillars can support the weight of several cars without collapsing.
I believe if it is done right (well thought out beforehand, and carefully fitted together without cutting the roof perimeter reinforcement of the 240) the result would be adequately strong for regular use, though crash safety might be slightly impaired.
Another thing to look for when examining the hole in the top of the VW---if there is a raised rim or flange of any kind around it, you will want to cut that off, and weld it on to the Volvo, so that the top will seal properly. As others have mentioned, water leaks could be a problem with this conversion.
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