(1) Determine the length of rail (1) to be removed and mark where the cut is to be made.
(2) Remove rivets (2) securing the top rail to side panel (3) and roof stringers as required. Remove any
foam, lining and/or other parts which block access to the repair area.
(3) Separate top rail (1) from roof (3) and side panels (4) with wedges no more than 5/32 in (4 mm) thick.
(4) Using a disc grinder, cut out the damaged area. Be careful not to damage adjoining component parts.
(5) Straighten the remaining rail edges if bent.
(6) Clean and smooth all cut edges with a disc grinder.
(7) Cut to size, clean and fit replacement insert. The insert must fit flush with the original rail. Allow no
more than 5/64 in (2 mm) clearance between adjoining surfaces.
(8) Tack weld into position, check alignment and continuously weld.
(9) Fasten rail (1) to side panels (4) and roof (3) with rivets (2). Install barrier tape to prevent contact
between dissimilar metals.
(10) Clean, mask, prime and top coat the repaired area.