Front Torque Box Flange Repair Guidelines

Explains what portions of the Front Torque Box flange can be repaired, and provides the repair instructions.

The criteria to determine if the Front Torque Box flange is repairable or if the Front Torque Box must be replaced are based on both the severity and the location of the damage. Use the images and information below to determine if the Front Torque Box flange may be repaired or if the Front Torque Box must e replaced.

Repair Criteria

The images below show several different sides of the Front Torque Box, and contain highlighted areas. Compare the damaged area of the vehicle's Front Torque Box to the images below, then use the repair criteria corresponding to the color of the highlighted area to find the criteria to use to determine if the damaged area of the Front Torque Box can be repaired.

Torque Box Flange Repair – Top View (LH)

Torque Box Flange Repair – Top View (RH)

Torque Box Flange Repair – Bottom View (LH)

Torque Box Flange Repair – Bottom View (RH)

Torque Box Flange Repair – Inboard View (LH)

Torque Box Flange Repair – Inboard View (RH)

Torque Box Flange Repair – Outboard View (LH)

Torque Box Flange Repair – Outboard View (RH)

Torque Box Flange Repair – Outboard ISO View (LH)

Torque Box Flange Repair – Outboard ISO View (RH)
Table 1. Allowed Repairs
Area Color Allowed Repairs
Orange areas:
  • For damage up to 40 mm. in length, heat and straighten damage.
  • Smooth sharp edges.
  • Rebuild flange with welding wire. See Rebuild the Flange with Welding Wire for more information.
  • Install a reinforcement plate (Tesla part number 1076938-E0-B). See Installing a Reinforcement Plate for more information.
  • For damage more than 40 mm. in length, the component is not repairable. Replace the Front Torque Box.
Red areas: Not repairable. Replace the Front Torque Box.

Rebuild the Flange with Welding Wire

Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.

  1. Use a heat gun to heat the damaged area.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not heat any adhesive joints of components that are not being removed. Heating adhesive joints weakens the adhesive bond and could compromise vehicle crash integrity.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not heat the adhesive on a bonded panel above 100°C (212°F) unless that panel is being removed. Heating the adhesive above 100°C (212°F) can weaken the adhesive bond and compromise vehicle crash integrity.
  2. Use a hammer and dolly or pliers to straighten the damaged area.
  3. Remove material containing cracks and smooth any remaining sharp edges in the repair area.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Use only sanding wheels and belts that are 80 grit or finer on aluminum components. Using sanding wheels or belts that are coarser than 80 grit can cause fractures in the aluminum.
  4. Use dye penetrant on the repair area to check for micro cracks in the aluminum.
    Informational PurposesAn informational icon, calling your attention
    Note
    If a crack is found, refer to the Repair Criteria above to determine what level of repair is necessary.
  5. Remove any factory self-piercing rivets present in the weld repair area.
  6. Use a disc or belt sander with a surface conditioning abrasive product to remove all coatings in the immediate vicinity of the weld locations.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Use only sanding wheels and belts that are 80 grit or finer on aluminum components. Using sanding wheels or belts that are coarser than 80 grit can cause fractures in the aluminum.
  7. MIG weld the flange area, adding enough material to restore the flange to factory dimensions.
  8. Grind down welds to restore all components to their original dimensions.

Installing a Reinforcement Plate

Reinforcement plates may be installed on the Front Torque Box flange only as specified in the Allowed Repairs table (above) or at the direction of the Tesla Body Repair Support Team.
Informational PurposesAn informational icon, calling your attention
Note
Reinforcement plates on the Front Torque Box flange are not installed by welding; reinforcement plates are installed only with structural adhesive and rivets.

Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.

The following parts are needed:

Quantity Description Image / Notes
1 PLATE- SERVICE SIDE SILL ECOATED (Side Sill Reinforcement Plate)
2 Structural Rivet, 6.5 mm Short
Reinforcement plates on the Front Torque Box flange are installed as follows:
  1. Remove the Front Rail Outer Extension. Refer to the procedure appropriate for the vehicle being repaired:
  2. Straighten the area where the reinforcement plate will be installed.
    Informational PurposesAn informational icon, calling your attention
    Note
    The reinforcement plate will be installed behind the repair area of the flange according to the Repair Criteria.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not heat any adhesive joints of components that are not being removed. Heating adhesive joints weakens the adhesive bond and could compromise vehicle crash integrity.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not heat the adhesive on a bonded panel above 100°C (212°F) unless that panel is being removed. Heating the adhesive above 100°C (212°F) can weaken the adhesive bond and compromise vehicle crash integrity.
  3. If needed, repair the metal in the area where the reinforcement plate is to be installed. See Rebuild the Flange with Welding Wire for more information.
  4. Fabricate a reinforcement plate from the side sill backing plate similar to the one shown here.

    Informational PurposesAn informational icon, calling your attention
    Note
    The reinforcement plate must extend at least 25 mm beyond both edges of the repair area and must fit snugly against the back side of the flange.
  5. Trim and rework the reinforcement plate as necessary to snugly fit over the area to be reinforced, and allow for any adjoining panels.
  6. Clamp the reinforcement plate in position behind the repair area of the flange according to the Repair Criteria.
  7. Position the Front Rail Outer Extension.
  8. Create 6.7 mm. holes for the structural rivets.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not install rivets in the repair area or within 13 mm. of the edges of the repaired area.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rivets locations securing the reinforcement plate must not interfere with rivets used for installing the Front Rail Outer Extension.
  9. Prepare the Front Rail Outer Extension for installation as directed.
    Informational PurposesAn informational icon, calling your attention
    Note
    When preparing the Front Rail Outer Extension for installation, do not drill holes for rivets in the repaired area.
  10. Prepare the surfaces for adhesive. See Preparing Mating Surfaces for Adhesives (Non–Welded Components) for more information.
  11. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  12. Put the Front Rail Outer Extension and fabricated reinforcement plate in position and secure them in place.

  13. Install the fasteners in the Front Rail Outer Extension.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    When installing fasteners in the Front Rail Outer Extension, do not install structural rivets in the repaired area.
  14. Install the rivets in the Front Torque Box flange reinforcement plate.

    or Structural Rivets, 6.5 mm Short

  15. Complete the installation of the Front Rail Outer Extension.

For assistance, contact your local Tesla Body Repair Support Team.