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Yikes. Nasty Surprise. My 67 wagon had bad floorpans and baseball sized holes rusted through the fenders, but nothing like that.

Nobody seems to have mentioned it, but 1964 was the last year that the volvos had the inferior rustproofing. 1965 onward are supposed to hold up much better. Still, comparable to the 544s, they say that the 100-series cars could be half rusted and still have a solid body.

Check out Mike Dudek (sp?) you can get 1800 series replacement spars that ought to go right into the 120. I was also told by other BB'ers that some repairs have involved building a "U-shell" around a damaged spar or crossmember.

I was sourcing such things when I discovered that my 73 1800ES was like this:


That's the main transverse crossmember under the seats. The rockers were unspeakable and the lower spars were shells held together by the undercoating.

If I knew how to weld, I would have saved it. It had a perfect interior.

Good luck. I'll try and save the proper bits for you *if* I have to disassemble the 65.