CARGO BED COVER (CBC), TYPE IV, 5 T CARGO TRUCK, MTV, AND MTV TRAILER
Cut an opening that is one inch larger than the damaged area, through panel skin with a portable electric
router equipped with a straight or spiral fluted (pull down) bit, or other aluminum cutting equipment such
as aviation metal snips. Avoid sharp corners in opening.
Peel damaged portion of skin from core by lifting and rolling skin.
Remove all loose core from exposed core area with compressed air.
Cut aluminum patch (1) one-inch larger all around than cutout opening.
Layout and drill holes (2) as shown.
Two part epoxy adhesive is flammable and toxic and shall be used only
in a well-ventilated area away from all sparks or open flame. Gloves and
safety goggles should be worn during use.
Mix a quantity of the adhesive in accordance with manufacturers instructions, components (part "A" and
part "B") sufficient for the scope of the repair in an open top container. The two adhesive components are
different colors; part "A" is yellow and part "B" is blue. When properly and completely mixed, the color of
the adhesive is green. Personnel should mix the two parts until the adhesive is a uniform green, with no
streaks of yellow or blue.
Pack adhesive in core cells to fill exposed area above surface of panel skin.
Cure adhesive at room temperature (75 degrees F) for 72 hours. If a heat source is available, alternate
cures can be achieved by exposing the repaired area to 150 degrees F for 3 to 4 hours, or 200 degrees F
for 40 to 60 minutes. If 150 degree F or 200 degree F cures are used, allow additional time for repaired
area to warm to curing temperature. Ensure that the surface temperature of the CBC does not exceed
225 degrees F.
Sand cured adhesive with sandpaper to obtain a smooth contour with surface of panel skin.
Center patch (1) over adhesive-filled area and mark patch outline (3) on panel skin.
Sand all paint from damaged panel skin within marked area.
Center patch (1) over filled area and drill No. 30 diameter holes (5) in panel skin. Use holes (2) in patch
as a template.
Index patch (1) and panel skin with a mark to allow patch to be replaced in same orientation.
Deburr all drill holes.