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			Approved Welding Wire	Cold Repairs Allowed	Heat Repairs Allowed	Maximum Heat	Heat Cycles Allowed
	Spot Welding	GMA Welding
		Plug	Butt Joint
5xxx Aluminum				ER4145			212°F (100°C)	N/A
6xxx Aluminum				ER4145			212°F (100°C)	N/A
Extruded Aluminum				ER4145			212°F (100°C)	N/A
Cast Aluminum				ER4145			212°F (100°C)	N/A
High-Strength Steel				Bohler Union X96			1200°F (650°C)	90 seconds (2 times)
Ultra High-Strength Steel				Bohler Union X96			N/A	N/A

Approved

Approved only as specified below

Not Approved

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

Many instances of non-structural damage to exterior body panels can be repaired to avoid panel replacement. In most cases, dents and tears in exterior 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.

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

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

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).

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

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.

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.

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.

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.

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

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

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.

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.

• Do not attempt to repair Ultra High-Strength Steel components, unless explicitly allowed by the repair procedure for the component.
• 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.