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Fig. 7  Service Fender and Damaged Hood Assembly
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TM-5-4210-230-14P-1 Aerial Ladder Fire Fighting Truck Manual
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REPAIRING SHEET METAL WITH FIBERGLASS
TRUCK SERVICE MANUAL TM 5-4210-230-14&P-1 BODIES AND CABS 6. After  clamping  fender  to  hood  on  D-400  series  check position  of  lower  corner  of  inside  rear  reinforcement channel.        In    some    cases,    the    rear    reinforcement channel    corner    will    not    line    up    with    inside    hood channel.  See Fig. 10.  This is due to slight variations of  hoods.    To  position  correctly,  cut  off  reinforcement for reinstallation after fender has been attached. 7. Drill  holes  from  inside  of  hood  through  fender  flanges for  installation  of  No.    10  sheet  metal  screws  to  hold fender in place.  Holes should be spaced 3 to 4" apart. Observe fender alignment to hood.  See Fig. 11. Fig. 11   Service Fender Mounting. 8. Grind  or  buff  all  joining  edges  and  radius  to  normal thickness  on  cowl  contours.  Blow  off  all  surfaces  and corners.  Clean with acetone on a soft cloth. 9. Cut  several  four  inch  strips  of  mat  material  (2"  each side   of   seam).      Then   on   a   piece   of   polyethylene position   two   layers   of   mat   saturated   with   the   resin mixture.   Apply   resin   mixture   to   the   inside   of   hood where material is being repaired.  When tacky, position the  strips  (2  layers)  over  seam.    Use  the  polyethylene to  press  out  air  bubbles.    Allow  to  cure..    Additional coats of the resin mixture may be applied to the area if desired.  NOTE: If holes are left where the new fender may  not  cover  the  damaged  area,  repair  these  places as outlined in instruction for repairing holes. 10. Refer   to   item   6.      If   required,   remount   inside   rear channel reinforcement corner. Grind edges and mounting surfaces for proper bonding.  Apply saturated sections of  mat  to  all  edges  and  seam  to  hood  channel.    If corner  positions  correctly  as  applied  on  fender,  apply mat   required   to   joining   seam   only.      Brush   out   air bubbles with a squeegee. 11. Before   proceeding   on   outside   repairs,   allow   inside sections  to  harden.    To  speed  drying  or  curing  time, apply heat with lamps.  No further inside refinishing is required.  Surfaces may be undersealed. 12. Grind off outside screw threads holding fender in place just  below  seam  surface.  Take  grinder  or  sander  and dish   out   concave   strip   approximately   one   inch   wide along hood and fender seams. 13. Apply one four inch strip of mat saturated with the resin along  concave  hood  and  fender  seams.    Next  apply  a four inch strip of cloth saturated with the resin mixture to  the  fender  seams  for  additional  strength.    Use  a squeegee or polyethylene sheet to force out entrapped air.  Allow time for assembly to cure.  Trim off any mat overhang at edges. 14. Grind   or   sand   all   outside   hood   and   fender   joined laminated seams.  See Fig. 12 Fig. 12   Service Fender and Hood Refinishing. 15. With plastic putty fill any existing low spots or surface cracks  with  plastic  putty.  16.    Sand  the  entire  exterior smooth, using a #400 grit paper.  See Fig. 12.  Clean surface  with  acetone  or  lacquer  thinner.  Apply  prime coat   and   follow   with   standard   automotive   refinishing procedures. See Fig. 13. CTS-2408  Page 6 PRINTED IN UNITED STATES OF AMERICA

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