Body Structure Materials and Allowed Operations

Materials Used in the Body Structure

The body structure of a Model S is composed of components made from varying grades of aluminum or steel. Metal components might be stamped, cast, or extruded. The materials of the components in the repair area determine the type of operations that can be performed.

Use the table and diagrams below to determine the component material and the allowed operations before beginning a repair. For each type of material, additional repair guidelines can be found in the appropriate section of this document.

Table 1. Allowed Operations on Body Structure Materials
Material	Allowed Welding Methods			Maximum Heat	Heat Cycles Allowed
	Spot Welding	GMA Welding
	Spot Welding	Plug	Butt Joint
5xxx Aluminum				212°F (100°C)	Any
6xxx Aluminum				212°F (100°C)	Any
Extruded Aluminum					Any
Cast Aluminum				212°F (100°C)	Any
High-Strength Steel				1200°F (650°C)	90 seconds (2 times)
Ultra High-Strength Steel


Approved	Approved only as specified below	Not Approved

Note

Refer to “Approved Gas Metal Arc (GMA) Welders and Welding Wire,” for a list of approved GMA welders and GMA welding wires.

Note

Refer to “Approved Squeeze-Type Resistance Spot (STRS) Welders,” for a list of approved squeeze-type resistance spot welders.

Body Structure Materials Diagrams

Use the color codes below in conjunction with the diagrams to determine the component material.

Table 2. Body Structure Materials Color Codes
Cast Aluminum	Extruded Aluminum	5xxx Aluminum
6xxx Aluminum	High-Strength Steel	Ultra High-Strength Steel

General Repair Limitations

Refer to Structural Repair Guidelines for information on allowed repair operations.

Note

A damaged part that has an attached crash sensor cannot be repaired; replace the damaged part instead.

Repairing Cosmetic Damage

Many instances of non-structural damage to body panels can be repaired to avoid panel replacement. In most cases, dents and tears in body panels can be successfully repaired by a technician with the appropriate skills and dedicated hand tools. Even significant cosmetic damage can be successfully repaired with basic metal-finishing skills.

Warning

Structural components may not be reshaped or repaired unless specified in the Part Repairability Guidelines.

Note

Follow all manufacturer's instuctions and safety guidelines when using tools to reshape body panels.

It is possible to repair common damage types in body panels, such as:

Tears in the quarter panel
Dents in the quarter panel
Puncture tears

Reshaping of exterior body and closure panels using the following tools is allowed.

Hand tools (including, but not limited to, weld-on tabs, glue-on tabs, hammer and dolly, paintless dent repair tools, etc.).
Tension towers, which use mechanically applied tension to reshape the panel.
Note
Hydraulic equipment intended for structural pulling may not be used to perform repairs.
Note
Frame-mounted tension towers may not be used.

The following panels may be reshaped using a tension tower:

Body Side Outer Assembly
Hood (exterior panel only)
Trunk (exterior panel only)
Door (exterior panel only)
Fender (exterior panel only)
Liftgate (exterior panel only)

Note

No other panels or components may be reshaped using a tension tower.

Body panels of the following materials may be reshaped using hand tools or tension towers:

5xxx Aluminum
6xxx Aluminum
Mild Steel

Safety Systems

Do not perform repairs on damage to body or structural components in the vicinity of safety related components such as airbags, seatbelts, impact sensors, intrusion beams etc. (replace the damaged body or structural component instead).

Adhesive Bonds and Factory Welds

If any factory adhesive bonds are compromised due to the original damage or during repairs, replace the panel.

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.

If any factory welds are compromised from the original damage or during repairs they must be replaced with an approved replacement fastening method which can be found in the repair procedure for the panel in question.

Paintless Dent Repair

As long as holes are not drilled in any panel for tooling access, paintless dent repair techniques are an acceptable method for repairing cosmetic panel damage.

Repair Guidelines for 5xxx Series Aluminum

5xxx series aluminum has a yield strength range from 100-150 MPa. Follow the guidelines below when repairing or replacing components composed of 5xxx series aluminum.

Repairs can be performed to address panel deformation and restore the panel to its original dimensions unless the damage includes creases or kinks. If the damage includes creases or kinks, replace the component.
Sectioning or partial replacement is acceptable only at approved locations and as specified in the repair procedure.
GMA welding can be performed to repair tears no greater than 75 mm in length. If the tear is longer than 75 mm, replace the component.
GMA welding can be performed to repair a hole on closure panels (doors, hoods, and liftgates) so long as the following conditons are met:
- The hole is 12 mm or less in diameter.
- There are no panels underlying any portion of the hole.
Note
If the hole is larger than 12 mm in diameter, or there are panels underlying any portion of the hole, contact Tesla Collision Repair for assistance.

Repair Guidelines for 6xxx Series Aluminum

6xxx series aluminum has a yield strength range from 230-280 MPa. Follow the guidelines below when repairing or replacing components composed of 6xxx series aluminum.

Repairs can be performed to address panel deformation and restore the panel to its original dimensions unless the damage includes creases or kinks. If the damage includes creases or kinks, replace the component.
Sectioning or partial replacement is acceptable only at approved locations and as specified in the repair procedure.
GMA welding can be performed to repair tears no greater than 75 mm in length.
GMA welding can be performed to repair a hole on closure panels (doors, hoods, and liftgates) so long as the following conditons are met:
- The hole is 12 mm or less in diameter.
- There are no panels underlying any portion of the hole.
Note
If the hole is larger than 12 mm in diameter, or there are panels underlying any portion of the hole, contact Tesla Collision Repair for assistance.
GMA welding can be performed to repair a hole on the Body Side Outer so long as the following conditons are met:
- The hole is 8 mm or less in diameter.
- There are no panels underlying any portion of the hole.
Note
If the hole is larger than 8 mm in diameter, or there are panels underlying any portion of the hole, contact Tesla Collision Repair for assistance.
GMA plug welding and butt joint welding can only be performed as specified in the Tesla Collision Repair Manual using approved weld wire.
Weld repairs can only be performed on panels less than or equal to 1.2 mm in thickness, unless otherwise specified in the Tesla Collision Repair Manual.
After repairs are completed, check the repaired area for micro-cracking with dye penetrant.

Repair Guidelines for Extruded Aluminum

Repairs on extruded or cast aluminum components can only be performed as specified per component in the Tesla Collision Repair Manual.

Repair Guidelines for Cast Aluminum

Repairs on extruded or cast aluminum components can only be performed as specified per component in the Tesla Collision Repair Manual.

Repair Guidelines for High-strength Steel

High-Strength Steel has a tensile strength range from 300–700 MPa. Follow the guidelines listed below when repairing or replacing High-Strength Steel components.

Cold repairs can be performed to repair cosmetic damage, unless the damage includes creases or kinks. If the damage includes creases or kinks, replace the component.
Controlled use of heat can be used to repair cosmetic damage. Do not allow the component temperature to exceed 1200°F (650°C). Apply heat a maximum of 2 times or for a combined total of less than 90 seconds. If the repair cannot be performed within these guidelines, replace the component.
Sectioning or partial replacement is acceptable only at approved locations and as specified in the repair procedure.
Resistance spot welding can be used to replace factory spot welds, where applicable and as specified in the Tesla Collision Repair Manual.
GMA welding can only be performed as specified in the Tesla Collision Repair Manual.

Repair Guidelines for Ultra High-strength Steel

Ultra High-Strength Steel (also known as UHSS) has a tensile strength greater than 800 MPa. Follow the guidelines below when replacing Ultra High-Strength Steel components.

Note

For best results, use high quality tungsten carbide or Boron drill bits in combination with a drill equipped with a C-frame when drilling through components made of Ultra High-Strength Steel.

Do not attempt to repair Ultra High-Strength Steel components, unless explicitly allowed by the Part Repairability Guidelines.
Sectioning or partial replacement is allowed only at approved locations and as specified in the repair procedure.
Do not use Ultra High-Strength Steel for a backing plate, unless specified in the Tesla Collision Repair Manual.
Resistance spot welding can be used to replace factory spot welds, where applicable and as specified in the Tesla Collision Repair Manual.
GMA welding can only be performed as specified in the Tesla Collision Repair Manual.