TM 55-8115-203-23 & P
(g) Do not position an insert so that its upper or lower edge is closer than twelve inches from the corner
fitting. See figure 3.4, example E. Instead, extend the insert all the way to the corner fitting. An
insert which butts against the corner fitting must be at ]east twelve inches long.
(h) Do not use an insert which will extend over less than three inches of the exposed corner post cross
section. See figure 3.5, example A.
(i) Do not position an insert so that its vertical edge is on the outside corner of the corner post. See
figure 3.5, example B.
(j) Do not use an insert which extends across more than half of the corner post cross section. See
figure 3.5, example C.
Inserts must not stick out from the corner post. See figure 3.5, example D.
Remove damaged portion of corner post and prepare for inserting.
(a) Mark around the damaged area with chalk or scribe. Mark a rectangular, oval, or diamond shape
depending on the general shape of the damaged area. A rectangular shape will be easiest to work
(b) Tack weld guide bars in place to ensure straight cuts with an oxygen acetylene torch. Even,
accurate cutting will eliminate wide gaps between the corner post and the new insert.
(c) Cut out the damaged area with an oxygen acetylene torch.
Direct oxygen acetylene torch away from corner castings, side and end rails, and side and end
panels to prevent damage to any of these Darts.
Grind smooth all cut edges.
(a) Using guide bars, cut a replacement insert to the exact shape of the damaged area. The insert
material must be rolled steel with at least 110 lbs/sq. in. (50 kg/sq. mm) minimum tensile strength.
(b) Grind smooth cut edges of insert.
Fit and weld insert in place.
(a) Place insert to determine fit. Insert should be flush against the corner post edges
on all sides.
(b) Bevel edges of the insert and corner post cutout area to a thirty degree angle (See Figure 3-6).
(c) Tack weld insert in place.
(d) Continuously weld insert to corner post.