Preparing for Installation

To prepare the vehicle and the new component for installation, the following tasks might be necessary (the specific repair document will indicate which tasks are to be performed):

  • Positioning the new component.
  • Preparing for fastener installation.
  • Preparing a Butt Joint.
  • Preparing surfaces for welding.
  • Preparing mating surfaces for adhesives.

Once the vehicle and the new component are properly prepared, install the new component.

Positioning the New Component

  1. Once all prerequisites specified in the Repair Information section of the procedure have been completed, position the new component on the vehicle.
  2. Align all bolt hole locations and temporarily install bolts.
  3. If necessary, trim butt joint locations to achieve a good fit for welding.
  4. Clamp all mating surfaces.
  5. Install adjacent panels to check overall fitment (gap and flushness) of the new component.
  6. Reposition the new component as necessary to achieve best fit with adjacent panels.

Preparing for Fastener Installation

  1. Make sure the new component is properly positioned and secured on the vehicle.
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    Note
    Use the following best practices when performing preparation steps for fastener installation:
    • Use a temporary fastener such as a grip screw or Cleco fastener to keep drilled holes aligned when drilling multiple holes in a component.
    • Use a deburring tool to deburr the holes after they have been drilled or punched.
    • When drilling holes for countersunk rivets, drill holes at least 18 mm from corners or obstructions to provide enough clearance for the Microstop countersink cage assembly.
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      Note
      If the depth adjustment for the Microstop countersink cage assembly has not already been set, do the procedure in the Microstop Countersink Kit to adjust the tool.
  2. Mark all locations where fasteners will be installed on the new component and/or the vehicle as indicated in the repair procedure.
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    Note
    When the same joint or component is repaired in more than one Body Repair procedure, the fasteners specified to secure the joint or component may be different in each procedure. The difference is only to simplify the fasteners used in each procedure, and all specified fasteners are approved by Tesla for use in that location. Use any of the specified fasteners from any Body Repair procedure for that component or location.
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    Note
    When installing fasteners to replace factory rivets, match the number and location of the new fasteners to the number and location of the removed rivets, unless explicitly directed differently in the repair procedure.
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    Note
    When installing spot welds to replace factory spot welds, match the number and location of the new spot welds to the number and location of removed spot welds, unless explicitly directed differently in the repair procedure.
  3. Drill or punch holes for fasteners as specified in the repair procedure, or as specified below.
    Fastener Type Hole Size Notes
    4.8 mm Blind Rivet 4.9 mm  
    6.5 mm Blind Rivet 6.7 mm  
    4.8 mm Countersunk Rivet 4.9 mm Use a drill with the Microstop countersink cage assembly and a 4.9 mm countersink bit to drill countersink holes. Note that the countersink angle is 100 degrees.
    6.5 mm Countersunk Rivet 6.7 mm Use a drill with the Microstop countersink cage assembly and a 6.7 mm countersink bit to drill countersink holes. Note that the countersink angle is 100 degrees.
    Flow Form Rivet 8 mm Use a riveter designed for punching holes for rivets or drill holes with an 8 mm bit.
    Aluminum Plug Weld 9 mm Only for panels up to 1.6 mm. thick, or as directed in the repair procedure.
    Steel Plug Weld 6 mm Only for panels up to 1 mm. thick, or as directed in the repair procedure.
    Bolt Varies Drill the smallest hole that allows the installation of the bolt specified in the procedure repair instructions.
    5/16 in. HUCK BOM 9 mm  
    1/4 in. Pin and Collar 6.7 mm  
    5/16 in. Pin and Collar 8 mm  
    Rivnut M5 (KNURL,M5,0.50-2.54,STL,ZNNI-PLTSL) 7.75 mm Tesla part number 1026912-00-A
    Rivnut M5 (KNURL,M5,0.50-3.30 GRP L,STL,ZNC) 7.75 mm Tesla part number 1004296-00-A
    Rivnut M6 (THN,M6X1.0X2.0-5.0,G10,G0109) 10 mm Tesla part number 1038174-00-A
    Rivnut M8 (M8X1.25 RIVNUT [MAGNI 560]) 13.5 mm Tesla part number 1015948-00-A
    Rivnut M8 (NUT,RVT,RND,THN,M8-1.25X16[ST]-O-05) 11 mm Tesla part number 1014282-00-A
    Rivnut M8 (RIVNUT,FH,M8,3.5-5.5,[10],ZN) 13 mm Tesla part number 1469780-00-B

    For more information about fasteners, refer to "Approved Fasteners and Fastener Tools for Structural Repairs."

Preparing a Butt Joint

  1. Cut the new component slightly larger than specified in the repair procedure.
  2. Make sure the new component has been properly positioned and trimmed if necessary (see Positioning the New Component for more information).
  3. Remove the new component or components from the vehicle.
  4. Use a disc or belt sander with a surface conditioning abrasive product to remove the coatings on the inner and outer surfaces of the butt joint on the vehicle and the new component.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Remove the epoxy adhesive in a well-ventilated area. Wear suitable personal protective equipment.
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    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.
  5. If the internal body cavity in the butt joint area has been coated with cavity wax, remove the coating using isopropyl alcohol (IPA).
  6. If specified in the procedure, create a reinforcement plate to cover the exterior side of the butt joint:
    1. Identify a section from the old component or a remnant of the new component that closely matches the profile of the butt joint location on the vehicle.
    2. Cut a section of the length specified in procedure (or 40 mm if no length is specified) from the old component or the remnant of the new component.
    3. Trim and rework the reinforcement plate as necessary to snugly fit over the butt joint and closely fit adjoining panels.
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      Note
      Make sure the reinforcement plate allows access for trim, if necessary.
    4. Remove the new component and the reinforcement plate to prepare for installation.
  7. If specified in the procedure, create a backing plate to install behind the butt joint:
    1. Identify a section from the old component or a remnant of the new component that closely matches the profile of the butt joint location on the vehicle.
    2. Cut a section of the length specified in procedure (or 40 mm if no length is specified) from the old component or the remnant of the new component.
    3. Trim and rework backing plate as necessary to fill the gap behind the butt joint and closely fit adjoining panels.
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      Note
      Make sure the backing plate allows access for trim, if necessary.
    4. Remove the new component and the backing plate to prepare for installation.
  8. Position the reinforcement or backing plate on the vehicle and install it as specified in the procedure.
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    Note
    Reinforcement and backing plates that are not installed by GMA welding are installed with structural adhesive and fasteners specified in the procedure.
    For backing plates: If the procedure does not specify a fastening method for the backing plate, install it using plug welds on both sides of the butt joint:
    1. Drill a plug weld installation hole every 25 mm along the length of the section location on the vehicle. If the repair procedure specifies:
      • Aluminum plug welds, drill 9 mm plug weld installation holes.
      • Steel plug welds, drill 6 mm plug weld installation holes.
    2. For steel components only: Apply weld-through primer to both sides of the backing plate and allow sufficient time for the primer to cure.
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      Note
      Follow surface preparation instructions for the specific product being used to ensure proper coating adhesion and performance.
    3. For steel components only: Use a disc or belt sander with a surface conditioning abrasive product to remove the weld-through primer on the outboard surfaces of the backing plate only in the weld locations.
    4. Install the backing plate using plug welds on both sides of the butt joint.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not weld on a Tesla vehicle before performing the Vehicle Electrical Isolation Procedure (refer to the vehicle-specific Service Manual for more information on the Vehicle Electrical Isolation Procedure). Welding on a Tesla vehicle with an energized high or low voltage system might damage vehicle components.
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      Warning
      Failure to follow all welding safety precautions, including the use of personal protective equipment, could result in serious injury or property damage. Only technicians who have completed Tesla’s approved welding training are authorized to weld structural components on Tesla vehicles.

Preparing Surfaces for GMA Welding

  1. Identify all weld locations on the vehicle and the new component.
  2. Remove the new component or components from the vehicle.
  3. Use a disc or belt sander with a surface conditioning abrasive product to remove all coatings on the top and bottom sides of the panels in the immediate vicinity of any weld location.
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    Warning
    To avoid the risk of galvanic corrosion, do not remove e-coat in any location where steel and aluminum will be in contact.
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    Warning
    After securing the component, no structural adhesive may be within 25 mm of any GMA weld location (structural adhesive within the GMA weld location can cause weld failure).
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    Warning
    When the panel is to be secured using GMA welding (plug welds), do not apply a bead of structural adhesive on top of the structural adhesive primer layer.
  4. For plug welds on steel components only: Apply weld-through primer.
    1. Follow surface preparation instructions for the specific product being used to ensure proper coating adhesion and performance.
    2. Apply weld-through primer to the exposed metal surfaces between the panels in the plug weld area where adhesive cannot be applied and allow sufficient time for the primer to cure.
    3. Use a disc or belt sander with a surface conditioning abrasive product to remove the weld-through primer at the plug weld locations.

Preparing Mating Surfaces for Adhesives and Resistance (Spot) Welding

  1. Identify all weld locations on the vehicle and the new component.
  2. Remove the new component or components from the vehicle.
  3. Use a disc or belt sander with a surface conditioning abrasive product to remove all coatings on the top and bottom sides of the panels in the immediate vicinity of any weld location.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    To avoid the risk of galvanic corrosion, do not remove e-coat in any location where steel and aluminum will be in contact.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use only insulated clamps within 200 mm (8 in) of resistance spot weld locations. Do not perform resistance spot welding when there is a shunting (uninsulated) clamp within 200 mm (8 in) of the spot weld location.
  4. Clean all the mating surfaces and weld areas on the new component or components and on the vehicle with isopropyl alcohol (IPA).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Wipe off the remaining isopropyl alcohol with a clean, dry towel immediately after application. Do not let the remaining isopropyl alcohol air dry. Allowing the remaining isopropyl alcohol to air dry can compromise the adhesive bond.

Preparing Mating Surfaces for Adhesives (Non–Welded Components)

  1. Identify all mating surfaces on the vehicle and the new component, take special note where different metals are being bonded together.
  2. Remove the new component or components from the vehicle.
  3. Remove any contaminants from the mating surfaces on the new component by cleaning them with isopropyl alcohol (IPA) prior to preparing the surface.
  4. Use a red Scotch-Brite pad or equivalent to abrade the e-coat on the mating surfaces of the new component and the vehicle.
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    Note
    It is not necessary to remove the e-coat completely, only roughen the surface of the e-coat in the mating areas to allow the structural adhesive to grip the component.
  5. Clean all the mating surfaces and weld areas on the new component or components and on the vehicle with isopropyl alcohol (IPA).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Wipe off the remaining isopropyl alcohol with a clean, dry towel immediately after application. Do not let the remaining isopropyl alcohol air dry. Allowing the remaining isopropyl alcohol to air dry can compromise the adhesive bond.