Sill Repair Guidelines

Explains how to determine if the Sill can be repaired or if replacement is necessary.

The images below show the Sill from different angles, and contain highlighted areas. Compare the damaged area of the vehicle's Sill 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 component can be repaired.


View	LH Component
Top
Bottom
Front
Rear

Based on the colors used in the images above, the allowed repairs are as follows:

Table 1. Allowed Repairs
Area Color	Allowed Repairs
Blue areas:	Sections that are broken off entirely can be welded back into place. Sections that are partially broken or cracked can be repaired by welding. Bent sections can be straightened using cold methods. Note Do not use heat methods to straighten sill sections.
Green areas:	Welding damage up to 50 mm is allowed. For damage more than 50 mm in length, contact Tesla Collision Repair for assistance. Bent webbing sections may be straightened using cold methods. Note Do not use heat methods to straighten webbing sections.
Orange areas:	Welding a crack up to 30 mm is allowed, but a reinforcement plate (Tesla part number 1076938-E0-B) must also be installed. See Installing a Reinforcement Plate for more information. For damage more than 30 mm in length, contact Tesla Collision Repair for assistance. Bent webbing sections may be straightened using cold methods. Note Do not use heat methods to straighten webbing sections.
Red areas:	None; if the component is damaged in these areas, contact Tesla Collision Repair for assistance.

Installing a Reinforcement Plate

Reinforcement plates may be installed only at the direction of the Tesla Collision Repair Support Team, or as specified in the Allowed Repairs tables (above). Reinforcement plates are installed as follows:

Note

Reinforcement plates are not installed by welding; reinforcement plates are installed only with structural adhesive.

Straighten the area where the reinforcement plate will be installed using cold methods.
Note
Do not use heat methods to straighten webbing sections.
Cut a section of reinforcement plate to length.
Note
Reinforcement plates are placed on both sides of cracked or straightened webbing. Make sure that each reinforcement plate covers the maximum surface area around the repair area.
Trim and rework the reinforcement plate as necessary to snugly fit over the area to be reinforced, and allow for any adjoining panels.
Remove any contaminants from the mating surfaces on the repair area and the reinforcement plate by cleaning them with isopropyl alcohol (IPA) prior to applying structural adhesive.
Apply structural adhesive.
Fit the reinforcement plates into position and clamp them into place.
Wipe off excess structural adhesive.

Warning

Before performing any repair that specifies to install fasteners through an already-installed reinforcement plate, contact Tesla Collision Repair for assistance. Because the reinforcement plate increases panel stack thickness, it may be necessary to change fasteners used in repairs performed after the reinforcement plate has been installed.