Repairing Aluminum Cosmetic Damage

Repair guidelines for exterior aluminum body panels.

In most cases, dents and tears on the aluminum outer panels can be successfully repaired by a technician with the appropriate skills and dedicated aluminum hand tools. As shown below, even significant cosmetic damage can be successfully repaired.

Figure 1. Damaged aluminum panels
Figure 2. Repaired aluminum panels

Common Repairable Situations

Many instances of non-structural aluminum damage can be repaired to avoid panel replacement. The sections below provide instructions on repairing three common situations:

  • Tears in the quarter panel
  • Dents in the quarter panel
  • Puncture tears
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Remove the paint in a well-ventilated area. Wear suitable personal protective equipment.
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.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Failure to follow all welding safety precautions, including the use of personal protective equipment, could result in serious injury or property damage.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Do not weld on a Tesla vehicle with an energized high voltage or low voltage system. Welding on a Tesla vehicle with an energized high or low voltage system might damage vehicle components. Perform the Vehicle Electrical Isolation Procedure before welding. Refer to the Service Manual for instructions.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Never use tools on aluminum components that have been used on steel components. Using tools on aluminum that have also been used on steel components can lead to galvanic corrosion and failure of the repair.
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.
Informational PurposesAn informational icon, calling your attention
Note
Before GMA welding, a test weld using material of the same gauge and type should be performed to make sure that the welding equipment settings produce a satisfactory joint.
Informational PurposesAn informational icon, calling your attention
Note
Although any aluminum panel dent pulling tool can be used to perform aluminum cosmetic repairs on Tesla vehicles, Tesla has evaluated and recommends the Star Miracle system.

Tears in the Quarter Panel

When there is an impact on the rear fascia, the force of the impact often causes a tear on the quarter panel near the fascia. These tears can usually be successfully repaired.

Figure 3. Torn quarter panel
  1. Inspect the back side of the panel being repaired before starting and remove any sound-absorbing material, sensors, or modules that are in the immediate area of the repair.
  2. Disconnect high and low voltage power using the "Vehicle Electrical Isolation Procedure" as described in the Service Manual.
  3. Remove the paint from the area around the tear and from the area where the ground clamp will be attached.
    Figure 4. Remove paint from the damaged area
    Figure 5. Remove paint from the ground clamp attachment area
  4. Use a stainless steel brush to remove any remaining paint from the repair area.
    Figure 6. Use a stainless steel brush to remove paint from the repair area
  5. Attach the ground clamp.
    Figure 7. Attach the ground clamp
  6. Assess where to attach the first pull tab.
    Tip: This is usually at the deepest point of the repair area.
  7. Use an aluminum dent repair system to weld a pull tab.
    Figure 8. Weld on a pull tab
  8. Use the appropriate tool to pull on the pull tab.
    Figure 9. Pull on the pull tab

    If necessary, use a heat gun to heat the panel to make it easier to pull the panel back into its original shape.

    Figure 10. Heat the panel
  9. Repeat steps 7 and 8 until the panel has been returned to its original shape.
  10. Remove all pull tabs and grind down any remaining pull tab material.
    Figure 11. Remove pull tabs
    Figure 12. Grind down remaining pull tab material
  11. Use the appropriate welding technique for a thin aluminum panel to weld the tear.
    Figure 13. Weld the tear (1/2)
    Figure 14. Weld the tear (2/2)
  12. Use a stainless steel brush to clean the repair area.
    Figure 15. Clean the repair area
  13. Grind down the welds to restore all components to their original dimensions.
    Figure 16. Grind down the welds
  14. Use an appropriate tool to identify any high spots, and then file down the high spots.
    Figure 17. Identify any high spots
    Figure 18. File down high spots
  15. Put the rear fascia into position to make sure the fit matches the undamaged side of the vehicle.
  16. If necessary, apply glazing putty to any deep scratches.
  17. Prime and paint the repaired area according to the paint manufacturer’s recommendations.
  18. Apply a suitable cavity wax or body filler to the back side of the repair area to help prevent corrosion.

Dents in the Quarter Panel

  1. Inspect the back side of the panel being repaired before starting and remove any sound-absorbing material, sensors, or modules that are in the immediate area of the repair.
  2. Disconnect high and low voltage power using the "Vehicle Electrical Isolation Procedure" as described in the Service Manual.
  3. Remove the paint from the repair area and from the area where the ground clamp will be attached.
  4. Use a stainless steel brush to remove any remaining paint from the repair area.
  5. Attach the ground clamp.
  6. Assess where to attach the first pull tab.
    Tip: This is usually at the deepest point of the repair area.
    Informational PurposesAn informational icon, calling your attention
    Note
    If a bodyline is present, it might be necessary to pull on that location to relieve stress on the other areas of the dent.
  7. Use an aluminum dent repair system to weld a pull tab.
    Figure 19. Weld on a pull tab (1/2)
    Figure 20. Weld on a pull tab (2/2)
  8. Use the appropriate tool to pull on the pull tab.
    Figure 21. Pull on the pull tab

    If necessary, heat the panel to make it easier to pull the panel back into its original shape.

    Figure 22. Heat the panel
    Tip: Use a hammer to tap around the edge of the tab to release tension while pulling.
  9. If necessary, use a hammer to flatten the bottom edge of the dent.
    Figure 23. Flatten the bottom edge of the dent
  10. Repeat steps 7–9 until the panel is back to its original shape.
    Tip: Work from the deepest point of the dent, and then move outwards.
  11. Remove all pull tabs and grind down any remaining pull tab material.
    Figure 24. Grind down remaining pull tab material
  12. Use an appropriate tool to identify any high spots, and then file down the high spots.
    Figure 25. File down high spots
  13. If necessary, apply glazing putty to any deep scratches.
  14. Prime and paint the repaired area according to the paint manufacturer’s recommendations.
  15. Apply a suitable cavity wax or body filler to the back side of the repair area to help prevent corrosion.

Puncture Tears

  1. Inspect the back side of the panel being repaired before starting and remove any sound-absorbing material, sensors, or modules that are in the immediate area of the repair.
  2. Disconnect high and low voltage power using the "Vehicle Electrical Isolation Procedure" as described in the Service Manual.
  3. Use a sanding block over the repair area to identify low spots.
  4. Use a paintless dent removal (PDR) bar and a hammer to remove any dents from the tear area until the area is as close to its original shape as possible.
    Figure 26. Restore the area to shape (1/2)
    Figure 27. Restore the area to shape (2/2)
  5. Use a wire wheel to remove any remaining paint from the repair area and the area where the ground clamp will be attached.
    Figure 28. Remove remaining paint from the repair area
  6. Attach the ground clamp.
  7. Use the appropriate welding technique for a thin aluminum panel to weld the tear.
    Informational PurposesAn informational icon, calling your attention
    Note
    Before MIG welding, a test weld using material of the same gauge and type should be performed to make sure that the welding equipment settings produce a satisfactory joint.
    Figure 29. Weld the tear
  8. Use a stainless steel brush to clean the repair area.
  9. Grind down welds to restore all components to their original dimensions.
  10. Use an appropriate tool to identify any high spots, and then file down the high spots.
    Figure 30. High spots removed
  11. If necessary, apply glazing putty to any deep scratches.
  12. Prime and paint the repaired area according to the paint manufacturer’s recommendations.
  13. Apply a suitable cavity wax or body filler to the back side of the repair area to help prevent corrosion.