Abstract: A method of reparing a worn flight bar is accomplished by first removing by torch cutting the worn ends of the flight bar. Replacement endpieces having an outer surface profile matching that of a new flight bar and an inner face configured to match the cut face of the flight bar ends are secured thereto by welding. Each profiled replacement endpiece is preferably formed by drop forging and contains welding chamfers and seating lands formed around the inner face thereof to insure strong weld joints and reproducible dimensional accuracy.