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TM5-4210-229-14&P
5-18.
CAB PANELS REPAIR.
This task covers:
a. Removal
b. Installation
INITIAL SET-UP
Tools
Materials/Parts
General Mechanics Tool Kit
Sandpaper (Appendix D, Item 46)
Heat Gun
Filler (Appendix D, Item 17)
Rubber Mallet
Putty (Appendix D, Item 44)
File
Paint (Appendix D, Item 40)
Grinder
General Safety Instructions
Engine OFF.
Transmission in (N) neutral
Parking brake set.
Batteries disconnected.
Battery selector switch OFF.
REPAIR
a.
Repair holes using metal insert.
(1)
Using the appropriate tools, cut the rusted or
damaged material from the panel.
(2)
Using a rubber mallet, form a step in the
original panel so that the new sheet metal or
aluminum insert will set flush with the original
panel.
Welding and brazing operations produce heat,
toxic fumes, radiation, metal slag, and carbon
particles. Welding and brazing goggles with the
proper tinted lenses, with gloves, apron or jacket,
and welders boots are required.
(3)
Cut a new sheet metal or aluminum insert to
fit within the step area of the panel being
repaired.
(4)
Attach the insert to the original panel by spot
or tack welding it in place.
(5)
Using a grinder, cut down the welds flush with
the exterior surface of the repair area.
(6)
To complete the repair, use the procedure for
Surface filling and finishing.
b.
Repairing dents.
(1)
Clean metal to the bare surface.
(2)
Drill or punch 1/2 inch holes in the dent to
assure a good anchor for the filler.
(3)
To complete the repair, use the procedure for
Surface filling and finishing.
c.
Surface filling and finishing.
After repairing the damaged areas, apply filler
(Appendix D, Item 17) and finish the surface as
follows:
(1)
Following the manufacturer's instructions, mix
enough body filler to re-establish the surface.
Mix filler on formica, teflon or other hard
surface. Do not work on a porous surface such
as cardboard.
(2)
Work the filler (Appendix D, Item 17) into the
repaired surface making sure to fill all voids
and remove larger air bubbles.
NOTE
Allow filler to extend above the original surface
to allow for shrinkage.
5-41
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