CAB BODY REPAIR
THIS WORK PACKAGE COVERS
General, Inspection, Rivet Replacement, Aluminum Repair
Tools and Special Tools
Tool kit, general mechanics (Item 132, WP 0126 00)
Drill, electric, portable (Item 31, WP 0126 00)
Drill set, twist (Item 32, WP 0126 00)
Riveter, blind hand (Item 109, WP 0126 00)
Compound, sealing (Item 14, WP 0125 00)
Tool kit, body and fender repair (Item 39, WP
The body is constructed from aluminum alloys that have been heat treated to obtain high strength. Welding cannot be
used to make body repairs. Heat generated in welding will reverse the heat treatment process and cause a great reduction
in strength of material.
The hood is made of SMC (sheet molding compound). Cracks, splits or holes may be repaired with a glass-reinforced
plastic laminate repair kit (WP 0106 00).
Solid 3/16-in diameter aluminum rivets are the primary method of joining body components. Rivets are inserted into a
hole through two pieces of metal. A second head is formed by manual or pneumatic impacting or by squeezing the rivet.
A bucking bar is used to back up the rivet to form the rivet head. When making repairs, use blind rivets of the same size
or oversize diameter with the appropriate grip length.
Blind structural aluminum rivets of 3/16-in diameter are used in applications where there is access from only one side of
the part. Blind rivets are installed using a tool that pulls on the rivet stem causing a bulbed head to form on the back side
of the part. Fastening is complete when the stem breaks off. High strength is obtained in blind structural rivets by
mechanically locking the remaining stem inside the rivet body.
Steel pull-type lock bolt fasteners in 3/16 and 1/4-in diameters are used where tension or high-shear loads exist. Lock
bolts are two-piece unthreaded fasteners. One part is a high-strength, steel-headed bolt-like part with serrations on its
shank. The mating part is a collar that is swaged over the serrations causing the fastener to be locked in place.
To facilitate repairs to the body, it is acceptable to replace lock bolts and rivets with 1/4 in AN4 series bolts. Do not
replace lock bolts with rivets. Standard threaded fasteners should not be used, as these will quickly wear the aluminum
structure. Bolt lengths should be chosen so that the cylindrical portion of the bolt is bearing on all members being
joined. Bolts are designated as NA4-XX or AN4C-XX, where XX defines grip length. Tighten all bolts to 70-75 lb-in (8
All riveted joints have adhesive foam between both components riveted together. The purpose of this tape is to ensure
watertight joints and to ensure aluminum components will not wear prematurely. Tape may be either 1 in or 2 in wide,
depending on the joint. Replace adhesive tape with the same size removed during disassembly. The only time adhesive
foam tape is to be replaced is if a riveted joint is completely taken apart.