CARGO BED COVER (CBC), TYPE IV, 5 T CARGO TRUCK, MTV, AND MTV TRAILER
Safety goggles must be worn during repair to protect eyes from flying
metal chips. Failure to wear proper eye protection may result in eye
injury and/or blindness.
Cut an opening through panel skin with portable electric router equipped with a straight or spiral fluted
(pull down) bit, or other aluminum cutting equipment such as aviation metal snips, that is one inch greater
than the damaged area. Avoid sharp corners in opening.
Peel damaged portion of skin from core by lifting and rolling skin with screwdriver and pliers.
Trim core area with a utility knife to same size as opening while leaving small amount of core material on
Cut a rectangular-shaped aluminum patch (1) 1-1/2 inch (3.8 cm), larger all around than cutout opening.
Lay out and drill 1/8 inch (3.18 mm) diameter holes (2) in patch.
Cut a section of core material the same size as cutout opening. Core plug should be flush with or slightly
lower than panel skin surface.
Center patch over cutout opening and mark patch outline (3) on panel skin. Drill No. 30 diameter holes in
panel skin with patch as template.
Do not use power sander when removing paint.
Sand all paint from panel skin within marked area with sandpaper.
Use facemask when sanding.
Index patch and panel skin with a mark to allow patch to be replaced with same orientation.
Deburr drill holes (2) and sand all paint from panel skin within marked area. Clean loose core material,
dust, and chips from cutout opening.