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.

This video shows how to use Polyvance's Kenworth T800 Hood Repair Kit to repair a broken Kenworth T800 hood.

We also have two kits for the Kenworth W900. We have one for hoods with round pockets and one for hoods with square pockets.

Always wear proper safety gear while working!

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The Kenworth T800 Hood Repair Kit Contains:

• One pair of aluminum hood pocket reinforcement plugs.
• One pair of steel reinforcement plates.
• 2 cartridges of 2510 PlastiFix High Performance Acrylic Adhesive.
• 2 mixer tips for 2510 PlastiFix High Performance Acrylic Adhesive cartridges.
• All of the required nuts, bolts, rivets, washers, and screws.

Tools Needed for the Repair (Not Included With the Kit):

• 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
• 3M 08571 Standard Manual Applicator Gun

Products Used:

Note: This is a list of the Polyvance products that can be used to make this repair. This list does not include sanders, grinders, or other common tools you will need. If you have any questions, please don't hesitate to call technical support at 800-633-3047.

• Kenworth T800 Hood Repair Kit (KEN T800)
• Cleaner: 1000 Super Prep Plastic Cleaner (several options available) OR 1001-4 EcoPrep Plastic Cleaner
• 2510 PlastiFix High Performance Adhesive

Video Notes:

• The EcoClean Plastic Cleaner seen in the video has been renamed EcoPrep Plastic Cleaner.
• English Closed Captions have been provided for this video. Click on the CC button to turn them on or off.
• The length of this video is in no way representative of the actual time required to perform a complete repair and therefore should not be used for estimating purposes.

English Transcript:

This video will show you the installation process for Kenworth T800 hood repair. This common hood damage can be repaired in a fraction of the time and cost.

First, clean the horseshoe pockets with plastic cleaner. Spray a heavy wet coat and wipe in one direction with a clean paper towel. Also, clean the reinforcing plugs to remove any oils or contaminants that might affect adhesion. Sand inside the horseshoe pockets by hand using 80 grit sandpaper. Remove any shiny surfaces to enhance adhesion. Sand the flat area on the hood with a 50 grit Roloc disc in an angle grinder. Remove the paint and roughen the surface for better adhesion. Using a 50 grit Roloc in an angle grinder, sand the outer surface of the reinforcing plugs. Also, remove the paint from one side of the bearing plate using the 50 grit Roloc.

Test fit the plug into the pocket; note that there is a driver's side and a passenger side. With the proper plug seated fully in the pocket, drill a one-eighth inch pilot hole in the middle, as shown. Prepare the adhesive tip by cutting the end off to create a larger hole. Break off the sealing tip of the cartridge by inserting a screwdriver to snap it off. Install the PlastiFix cartridge into the gun and balance the sides by squeezing a small amount of adhesive out. Screw on the mixer tip. Pump Plastifix adhesive through the mixer tip and generously coat the inside of the pocket. Pump adhesive over the outside of the plug. Spread the adhesive evenly over the plug and inside the pocket. Working time of the adhesive is about 15 minutes at room temperature.

Install the plug into the pocket. Hold it in place by installing a number 10 screw into the pilot hole you drilled earlier. Insert two bolts through the holes from the inside to serve as guides for the bearing plate. Slide the bearing plate over the bolts, hold in the proper position, then drill three-sixteenth inch holes for the rivets. Drill the first corner and loosely insert a rivet to hold it in place. Drill the second corner and do the same thing. Drill out the other two holes. Remove the plate and bolts. Fill the broken-out area with a generous amount of PlastiFix adhesive. Apply adhesive to the area where the bearing plate will be bonded.

Install the bearing plate by inserting four pop rivets into the holes you drilled earlier. Fill the gap between the plate and plug completely with PlastiFix. Clean up any excess with a gloved finger or body spreader. Let the PlastiFix adhesive cure at least two hours before installing brackets.

Re-drill the bolt holes with a five-sixteenth inch drill bit to clean out any adhesive. Install the brackets with the supplied bolts and nylock nuts. Use a flat washer under the bolt and nut. Now you're ready to get back on the road much faster, and at a much lower cost using Kenworth T800 hood repair kit.