sheet firmly while the other holes are reamed and
repair facilities, will be repaired by the commercial
riveted. Machine screws should be used only for
railway on a contract basis. Repairs to Army owned
temporary repairs when no riveting facilities are
passenger car superstructure usually will be limited to
available, or when a rivet cannot be used.
bodies, roofs, floors, etc., as required to keep the
equipment serviceable and safe for the movement of
d. Repairs to Roof. To gain access to the
underside of car roof, the interior ceiling finish must be
9-8. Repair Schedules
removed. Roof patches must be formed to the contours
of the roof and carefully fitted. Before the patch is
installed, the underside of the patch should be coated
a. General. Except in the case of accidents,
with a waterproofing compound.
passenger car superstructures require few extensive
tapped into the existing roof are generally used to
repairs during their first years of service. Normal
secure patches. Small defects may be repaired by
railway practice is to establish shopping cycles ranging
from 17 to 24 months, based on the type of service the
car is assigned to, -the length of the runs, etc. The
e. Repairs to Inside of Cars. Renewal or repair to
condition of wheels, trucks, and draft gear are
the inside finish of passenger-type cars usually is fairly
determining factors in shopping cars for repairs.
simple, as it is arranged in small sections or sheets. To
insure accurate fits, care must be used in renewing a
b. Procedure. All parts of the superstructure
piece. If holes are not properly alined, the section may
which cannot be repaired in place are removed. Window
buckle when installed. Sheets may be spliced by using
curtains, aisle strips, seat and back cushions, etc., are
a batten ,or reinforcing strip behind the butt joint. The
taken out and sent to their particular shops for repairs
batten should be drilled or tapped and the sheets
and renovation. Window sashes and doors are stripped
secured to the batten with countersunk head machine
of hardware for repair and repainting. Each part is
screws. Any empty holes resulting from relocation or
properly marked or tagged for correct replacement.
removal of equipment should be filled with solder and
Other items removed may include luggage racks,
scraped level with the surface.
mirrors, pipe covering, toilet fixtures, screens and
ventilations, or any specially installed equipment.
used for passenger car floors. If cracks occur, or it is
c. Renewing Side Sheets. Damaged or corroded
necessary to remove a section of the floor to make
sheets should be renewed. New sheets may be installed
underframe repairs, the floor must be patched. Repair
by riveting or by the use of machine screws. After the
material is mixed to the proper consistency, applied to
interior finish sheets have been removed, the rivets
the section being repaired land leveled with the old floor.
holding old side sheets may be cut off. It is usually
If a brass aisle strip passes through a section of floor
necessary to remove a few rivets in adjacent sheets to
being patched, the strip should be imbedded in the
release the old sheet. A template should be made so
cement when the patch is made.
that the new sheet can be cut and drilled accurately:
Drill the holes slightly smaller than required and ream
them to size after the new sheet is temporarily bolted
into place. Enough bolts should be placed to hold the
Section II. BOXCARS
9-10. Oversea Fleet
No all-wood boxcars are now in service in CONUS;
An estimated 35 to 40 percent of the 40-ton, knocked-
however, boxcars with steel under- frames and
down Army oversea fleet is boxcars. The 40-ton fleet
composite wood-steel superstructures are still used.
contains boxcars, gondola cars, and the basic flatcar.
The all-steel car is a rarity in most foreign countries;
The superstructure of the box- cars is designed to
most oversea boxcars are constructed with wood or
composite wood-steel superstructures.
any appreciable amount of the total loading. This
components of the Army oversea fleet have wooden
concept justifies the light framing of the boxcar
superstructures with steel under frames. Consequently,
superstructure and the use of plywood for inside lining
this manual will be largely limited to the types of boxcar
without the usual outside steel sheathing used on
that TRS car repair units in a theater of opera- tions
commercial equipment on railways in the United States.
would most likely be concerned with.
Field erection is expedited by the fact that