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Sorry, I suppose I should have replied to this sooner, I have pondered it for some time now... Is it at all possible for you to share some digital pictures of the damage with us? I have done very little searching for Volvo floor pans, so I don't know if they are available. I have installed plenty of floor pans in vintage Mercedes and Chevrolets, but have not had an oppurtunity to replace a floor in a Volvo, yet. I'm sure my time will come.
If you must do a patch job, do not use aluminum, it will turn to powder in short order. I do suggest use of POR-15, a rust-inhibiting paint. It's a little spendy, but works VERY well. New floor pans are always the best.
I guess it all comes down to how much you value saving that particular car.
Jerry
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