TM 55-203
5-9. Steel Splices
a. General. Frequently, underframe sills are cracked
or broken through deterioration, rough handling, or
accident. In many cases the crack or break is of such
proportion or in such a location that the whole member
must be replaced. In other cases the sill may be repaired
by "splicing." Where practicable and especially in a
theater of operations, splicing of sills is recommended.
Splicing may be done on a sill adjacent to another splice
or adjacent to a sill that is spliced Whether the break is on
the inside, outside, or completely through, the procedures
will be generally as explained in b, below. In all cases of
splicing, reinforcing cover plates must be used on each
side of the broken sill, over the fracture.
Figure 5-4. Marking with templates.
b. Center Sills. Before a broken sill is spliced,
measure the web and flanges A piece of steel plate as
thick as the sill to be spliced will be used in marking off
and cutting out the splice The location of rivet holes are
then marked off on the sill to be spliced Marking off may
be done by using a template as described in paragraph 5-
8a or by measuring and marking. After the splice plate is
put in place, the holes to be made are (marked for
punching or1 drilling Before any holes are made in the sill,
the adjacent broken parts of the sill must be drawn
together by bolts for butt-joint splicing These tie bolts hold
the sill until the splice is secured. In CONUS, AAR
regulations may require welding of the break before
Figure 5-5. Template for angle.
application of the splice cover plates As soon as the sill is
prepared, the cover plates are applied and riveted. The
riveting process is discussed in paragraph 5-19.
c. End and Side Sills. Because of the stresses land
strains to which the end sills are subjected, they are
frequently badly bent between the buffer and the corner of
the car. This damage may be repaired by placing a jack
against the bent part any applying heat to the sill with an
acetylene torch, at the same time tightening on the jack
as illustrated in figure 5-7. This usually will restore an end
sill to its original position. Side sills usually can be
straightened in a similar manner.
Small kinks in side and end sills may be straightened by
heating and hammering Broken side sills may be spliced
at any point between the end sills.
d. Crossbearers Defective Crossbearers usually are
cut out and replaced with new ones, since they connect to
the center and side sills. While it is a simple operation to
remove them, crossbearers may be patched if it can be
Figure 5-6. Templates for I-beam
done satisfactorily. Whether replaced or repaired, the
crossbearer must be removed by cutting the rivets
together In the middle of the frame with a pull jack. The
pull jack exerts a diagonal pull on the underframe,
bringing it back into square. Application of heat 'to the
center
sill
may
speed
the
operation.
5-5
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