TM 55-8115-203-23 & P
b. Inserting. If the damaged crossmember cannot be repaired by gouging and welding, repair the crossmember by
(1) Restrictions for insert repair of crossmembers are as follows.
(a) Do not use insert to repair damage to the top flange of the crossmember or the upper one half inch
of the vertical web. See figure 3-11.
(b) If damaged area is within six inches of an existing welded repair, the insert must butt up against the
existing weld. See figure 3-12, example A.
(c) If damaged area is within six inches of the bottom side rail, the insert must butt up against the rail.
See figure 3-12, example B.
(2) Remove damaged portion of crossmember and prepare for inserting.
(a) Remove undercoating from damaged area.
(b) 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
(c) Remove flooring next to damaged area in accordance with paragraph 2-10.
(d) Tack weld guide bars in place to ensure straight cuts with an oxygen acetylene torch. Even,
accurate cutting will eliminate wide gaps between the crossmember and the new insert.
(e) Cut out the damaged area with an oxygen acetylene torch.
(f) Grind smooth all cut edges.
(3) Cut insert.
(a) Using guide bars, cut a replacement insert to the exact shape of the damaged area.
(b) Grind smooth cut edges of insert.
(4) Fit and weld insert in place.
(a) Fit insert in place. Insert should be flush against the crossmember edges on all sides.
(b) Bevel edges of the insert and crossmember cutout area to a thirty degree angle (See figure 3-6).
(c) Tack weld insert in place.