Kenworth T800 Hood Repair Kit

The damage to Kenworth T800 Metton hood pockets is very common. So common, in fact, that Kenworth has a technical service bulletin (TSB) that addresses the issue of the damaged T800 hood guides. Their solution? Replace the hood! An OEM Kenworth T800 hood will set you back at least $5,000. Even an aftermarket fiberglass Kenworth T800 hood costs about $2,500. Polyvance has a much more economical solution to repair the damaged Kenworth T800 hood pockets. Polyvance's "Kenworth T800 Hood Repair Kit" will allow you to repair the damaged horseshoe-shaped hood pockets on your Kenworth T800 for a fraction of the cost of replacing your damaged Kenworth T800 hood.

Benefits:

• Save thousands over the cost of a new hood.
• Repairing the hood is faster than replacing the hood.
• With the Kenworth hood repair kit, there is no need to paint the hood. Replacing the hood requires you to paint the hood to match.
• Stronger than the original hood pockets. Load is spread out over a much larger area.
• Usually faster delivery times. Definitely cheaper shipping cost.
• Better design. If you replace the hood, you are putting on a new hood with the same poorly-designed hood pockets that will probably break again. The Kenworth hood repair kit is a better design as it converts the point load to a large-area load.
• This kit will get your truck back on the road quickly so you can continue making money. Every day that your truck is not on the road, you are losing money. Stop losing money. Repair your hood this morning and continue making money this afternoon.

The "Kenworth T800 Hood Repair Kit" contains:

• One pair of aluminum hood pocket reinforcement plugs.
• One pair of steel reinforcement plates.
• PlastiFix High Performance Acrylic Adhesive
• All of the required nuts, bolts, rivets, washers, and screws.

Tools/Products that you will need: (not included with kit)

• 
  Applicator Gun
• 
  1001-4 EcoPrep Cleaner
• Drill
• 5/16" Drill bit
• 3/16" Drill bit
• 1/8" Drill bit
• Phillips head screwdriver
• 50 grit Roloc disk and sander
• 60-80 grit sandpaper
• Rivet gun for 3/16" inch pop rivets

Instructional Video

Step-By-Step Instructions (Click on images to enlarge them)

Step 1

Clean both pockets and the surrounding area where the plate will be bonded in the hood with 1001-4 EcoPrep Plastic Cleaner.

Step 2

Hand sand the inside of the pockets with 60 to 80 grit sandpaper to roughen the surface and remove ALL paint.

Step 3

Grind the flat area where the plates will be bonded with a 50 grit Roloc disk, then blow the dust away.

Step 4

Clean the outside of the reinforcing plugs with 1001-4 EcoPrep Plastic Cleaner.

Step 5

Thoroughly grind the outside surface of the plug with a 50 grit Roloc disk to make the aluminum receptive to PlastiFix adhesive.

Step 6

Grind the paint off of one side of the bearing plate to improve adhesion. Blow the dust away. Do NOT clean with EcoPrep.

Step 7

Drill a 1/8" pilot hole into the plastic using the middle plug hole as a guide. Use the correct DRVR or PASS plug. They are different!

Step 8

Generously coat the plug and socket with enough PlastiFix adhesive to fill any gaps between the plug and the pocket.

Step 9

Spread the adhesive evenly over the plug and inside the socket. Working time is about 15 minutes at room temperature.

Step 10

Install the plug & use a #10 wood screw to secure the plug in position. Wipe up excess adhesive with a gloved finger or spreader.

Step 11

Using two 5/16" x 2" bolts as a guide for the bearing plate, drill the first 3/16" rivet hole into the hood. Note: The plates are identical.

Step 12

With a rivet temporarily placed in the first hole as a guide, drill the remaining rivet holes. Remove the plate, bolts, and rivet.

Step 13

Fill the broken-out area on the side of the plug with adhesive, then coat the sanded side of the bearing plate with adhesive.

Step 14

While pushing firmly down on the bearing plate, rivet the plate into place using four 3/16” rivets, one in each corner.

Step 15

Fill the gap between the plate and the plug completely with PlastiFix. Clean up excess with a gloved finger or body spreader. Let cure for 2 to 4 hours minimum at 70°F.

Step 16

Re-drill the bolt holes with a 5/16" drill bit.

Step 17

Install the hood brackets using the supplied 5/16" x 1-3/4" bolts, nuts, and washers. Use a flat washer under both the bolt head and lock nut.

Step 18

A job well done and ready for the road. Congratulations, you just saved a lot of time and money!

Before and After

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