Volvo 240 electrical question.
 

Helping brother with selling his Volvo. Problem with taillight wiring (notoriously bad on these cars). Factory design has a main plug that connects to an electrical copper "film" that goes to each light area upon which each bulb holder, by tension, makes electrical contact with the film. The problem appears to be with the main plug to film connection which fails if plugged all the way in and only works if partly plugged in (which then fails with vibration). Also is blowing fuse repeatedly. Have cleaned and checked all connections and it simply seems to be a poorly designed system.

As I want a cheap and problem-free fix, I am considering simply soldering the connections between each bulb holder and the main wiring (bypassing the main plug and the copper film set-up with a home-made wiring harness).

As I am not especially knowledgeable on electrical issues, I was hoping for knowledgeable advise on downside of this, if any. (Tried Brickboard search with no luck).

All help appreciated.

What Volvo model is it? I have an 89 245. My third brake light was coming on intermittently, but more off than on when I depress the brake pedal. It turned out that a strip of wire was not making a good contact. I just pressed on it toward the bulb socket and that fixed it. Does your bulb warning light come on or stay on? Try posting in brickboard.com They're great people!