CARGO BED COVER (CBC), TYPE IV, 5 T CARGO TRUCK, MTV, AND MTV TRAILER
Cut bonded sandwich panel (3) to same size as cutout opening as detailed in earlier step. Ensure core
ribbon direction is same as panel.
Cut two aluminum patches (7) 1-1/2 inch (3.8 cm) larger all around than cutout opening.
Layout and drill 1/8 inch (3.18 mm) diameter holes (4) in patches.
Position bonded sandwich panel (3) in cutout opening.
Center patches (7), one on each side of panel, over cutout opening.
Drill No. 30 (3.27 mm) diameter holes (8) in panel skins and bonded sandwich panel with patches as
Mark each patch outline (5) on panel skin and sand all paint from panel skin within marked area with
Index each patch and panel skin with a mark to allow patches to be replaced with same orientation.
Remove patches (7) and bonded sandwich panel (3).
Deburr drill holes (4,8) and sand all paint from panel skin within marked areas.
Clean loose core material, dust, and chips from cutout opening.
Wipe panel skin within marked areas (two patches) and bonded sandwich panel metal skin with a clean
cloth dampened with solvent. Immediately wipe solvent from surfaces with a clean, dry cloth.
Mix a sufficient amount of adhesive in accordance with manufacturer's instructions, as detailed above.
Apply a thick coat of adhesive to inside surfaces of panel cutout opening, bonded sandwich panel and
Position bonded sandwich panel in cutout opening.
Fill any gaps between cutout opening and bonded sandwich panel with adhesive.
Place patches (7) over prepared areas in same orientation as described in earlier step.
Align holes (4,8) and using hand blind riveter, install 1/8 inch (3.18 mm) diameter blind rivet (6), in
Clean repaired surfaces.
Caulk around repair patches (7) in accordance with WP 0025.
Apply alodine solution. Apply the alodine solution with a brush, paint spray gun, cellulose sponge, etc.,
to the cleaned and rinsed aluminum surface, liberally, quickly and evenly. Allow it to act from 1 to 5
minutes before rinsing.