TM 55-8115-203-23 & P
(7) Remove old caulking which would interfere with installation of new rail.
(8) Measure and cut replacement rail to exact length.
(9) Fit replacement rail in place. There should be no more than 5/64 in. gap between the rail edges,
crossmember ends, corner fittings, and side or end panels.
(10) Bevel to a thirty degree angle the end edges of the replacement rail according to figure 3-6.
(11) Tack weld the replacement rail in place. Check standard dimensions according to figure 3.1 and adjust
(12) Continuously weld the rail to the corner fittings, crossmembers and side or end panels.
(13) Paint the replacement area according to paragraph 2-4.
(14) Replace floorboards according to paragraph 2-10.
(15) Replace lower plywood liner according to paragraph 2-9.
3-7. Floor Crossmembers. Use repair procedures in the following order of preference: Fill with weld metal, welding
repair with inserts, patching with a full length overlapping angle and replacement of the complete floor crossmember.
All patches, inserts, sections and replacements for panels, rails and crossmembers should be
of 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 65 KSI
(thousand pounds per square inch).
a. Repair of Small Cracks and Tears. Small cracks and tears less than two inches in length should be filled with
(1) Carefully smooth ragged edges of tear with file or hammer before welding.
(2) Grind along length of crack. Grind crack to depth 3/16 in. (5 mm or 5/6 of metal thickness) to ensure full
(3) Continuously weld along length of crack.
(4) Paint according to paragraph 2-4.