TM 55-8115-203-23 & P
Continuously weld the J-bar in place.
Paint the repaired area according to paragraph 2-4.
Replace door according to paragraph 2-7.
3-5. Top Rail. Use repair procedures in the following order of preference: Filling with weld metal, welding repair with
inserts, sectioning, and replacing the top rail.
Direct oxygen acetylene torch away from corner castings, side and end rails, and side and end
panels to prevent damage to any of these parts.
Repair of small cracks and tears. Small cracks and tears less than two inches in length should be filled with weld
Carefully smooth ragged edges of tear with file or hammer before welding.
Grind along length of crack. Grind crack to depth of 3/16 in. (5 mm or 5/6 of metal thickness) to ensure
full weld penetration.
Continuously weld along length of crack.
Paint according to paragraph 2-4.
Inserting. If the damaged top rail cannot be repaired by gouging and welding the top rail may be repaired by
All patches, inserts, sections and replacements for panels, rails and crossmembers should be
steel conforming to the AISI-409 standard. AISI stands for the American Iron and Steel
Institute. This steel is corrosion resistant and has a minimum tensile strength of 65KSI
(thousand pounds per square inch).
Restrictions for insert repair of top rails are as follows.
(a) The insert must be at least six inches long. See figure 3-7, example A.
New inserts must end at least six inches from existing inserts or other vertical welded seams. If the
area to be repaired is closer than six inches to an existing vertical welded seam, the insert must
extend to meet the existing vertical welded seam. See figure 3-7, example B.