2025-04-25

Door Ring Outer

Repair Information

Any individual section or any combination of sections of the Door Ring Outer can be replaced so long as the referenced cut lines from the Door Ring Outer Section Descriptions portion of this document are used.
Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.
Properly mount the vehicle on a frame bench when performing this procedure.

Parts List


Quantity	Description	Image / Notes
1 Note For section repairs only: Some section repairs require a second part. Refer to the Door Ring Outer Section Descriptions to determine if the planned section repair requires an additional part.	ASSEMBLY - DOOR RING OUTER (Door Ring Outer)
2	Structural Bulb Rivet, 6.5 mm
29	High Strength Structural Rivet, 6.5 mm
13	Flow Form Rivet S18
39	Flow Form Rivet S28
2	Flow Form Rivet S38
15	Flow Form Rivet S48

Note

Rivet quantities listed above are for the complete repair. Refer to the Door Ring Outer Section Descriptions for fasteners required for section repairs.

When ordering parts, refer to the Parts Catalog and enter the VIN of the vehicle being repaired to find the correct parts (and the part numbers) for the vehicle. Alternatively, use the search function in the Parts Catalog to find a specific part for the vehicle.

Door Ring Outer Section Descriptions


Door Ring Outer, Subassemblies, and Subassembly Sectioning
The Door Ring Outer (shown below) is a single component, and can be replaced as a single repair:

Alternatively, instead of replacing the complete Door Ring Outer, areas of the Door Ring Outer can be replaced using portions of the Door Ring Outer using the cut lines described in this document.

Door Ring Outer Sections


Door Ring Outer Section Descriptions		Parts Required
Sill Front Section Cut Line Reference Line/Point A = 636 mm B = 589 mm C = 55 mm D = 84 mm Note Create a reinforcement plate 60 mm wide, and install it as indicated.		Structural Bulb Rivet, 6.5 mm – 12.
Hinge Pillar Section Cut Line Reference Line/Point E = 213 mm F = 99 mm Note Create a backing plate 80 mm wide, and install it as indicated. Note The rivet circled in red is installed after the Body Side Outer component has been installed.		Structural Bulb Rivet, 6.5 mm – 7. or Installation Spot Welds Note Order an additional Door Ring Outer when performing this section repair.
A–Pillar Section Cut Line Reference Line/Point G = 151 mm H = 78 mm Note Create a backing plate 80 mm wide, and install it as indicated.		Structural Bulb Rivet, 6.5 mm – 8. Rivet, 4.8 mm – 2.
B–Pillar Upper Section Cut Line Reference Line/Point I = 69 mm J = 62 mm Note Create a backing plate 80 mm wide, and install it as indicated.		Structural Bulb Rivet, 6.5 mm – 8. Rivet, 4.8 mm – 2.
B–Pillar Lower Section Cut Line Reference Line/Point K = 80 mm L = 127 mm Note Create a backing plate 80 mm wide, and install it as indicated.		Structural Bulb Rivet, 6.5 mm – 4. Rivet, 4.8 mm – 8. Note Order an additional Door Ring Outer when performing this section repair.
Sill Rear Section Cut Line Reference Line/Point M = 324 mm N = 359 mm O = 50 mm P = 80 mm Note Create a reinforcement plate 60 mm wide, and install it as indicated.		Structural Bulb Rivet, 6.5 mm – 10. Note Order an additional Door Ring Outer when performing this section repair.

Repair Procedure

If necessary, remove the necessary portion of the Shotgun Outer to expose the underlying component being replaced.
Remove the necessary portion of the Body Side Outer to expose the underlying component being replaced.
If replacing a section of the Door Ring Outer: Mark the Door Ring Outer at the section cut line locations described in the Door Ring Outer Section Descriptions.
Remove the original component.
- or Factory Spot Welds
Remove the original component.
- or Drill through factory spot welds
Note
When drilling out spot welds, use a drill bit that creates a hole correctly sized for the fastener that will replace the spot weld.
- or Factory Spot Welds
Remove the original component.
- or Drill through factory spot welds
Note
When drilling out spot welds, use a drill bit that creates a hole correctly sized for the fastener that will replace the spot weld.
- or Factory Spot Welds
Remove the original component.
- or Drill through factory spot welds
Note
When drilling out spot welds, use a drill bit that creates a hole correctly sized for the fastener that will replace the spot weld.
- or Factory Spot Welds
Remove the original component.
- or Factory Spot Welds
Remove the original component.
- or Drill through factory spot welds
Note
When drilling out spot welds, use a drill bit that creates a hole correctly sized for the fastener that will replace the spot weld.
- or Factory Spot Welds
For section repairs only: Create backing plates or reinforcement plates as described in the Door Ring Outer Section Descriptions.
Prepare for installation.
- or Installation Spot Welds
Note
Installation Spot Welds circled in red are to be spot welded over existing weld; all other Installation Spot Welds are installed offset 14 mm from the center point of the factory location.
- or High Strength Structural Rivets, 6.5 mm
- or Structural Bulb Rivets, 6.5 mm
Prepare for installation.
- or Installation Spot Welds
Note
Install all Installation Spot Welds offset 14 mm from the center point of the factory location.
Prepare for installation.
- Reference Line/Point
- or High Strength Structural Rivets, 6.5 mm Q = 30 mm
- or Flow Form Rivets, S18
- or Flow Form Rivets, S28
Prepare for installation.
- or Installation Spot Welds
Note
Install all Installation Spot Welds offset 14 mm from the center point of the factory location.
- or High Strength Structural Rivets, 6.5 mm
Prepare for installation.
- or Installation Spot Welds
Note
Install all Installation Spot Welds offset 14 mm from the center point of the factory location.
- or Flow Form Rivets, S28
Prepare for installation.
- or Installation Spot Welds
Note
Install all Installation Spot Welds offset 14 mm from the center point of the factory location.
- or Structural Bulb Rivets, 6.5 mm
Prepare for installation.
- or Installation Spot Welds
Note
Install all Installation Spot Welds offset 14 mm from the center point of the factory location.
- or Structural Bulb Rivets, 6.5 mm
Prepare for installation.
- or Installation Spot Welds
Note
Install all Installation Spot Welds offset 14 mm from the center point of the factory location.
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
For section repairs only: Install backing plates or reinforcement plates as described in the Door Ring Outer Section Descriptions.
Install the new component or components.
Perform resistance spot welding.
- or Installation Spot Welds
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.

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.
Install the portion of the Body Side Outer that was removed to expose the component being replaced.
Install the portion of the Shotgun Outer that was removed to expose the component being replaced.
Install the fasteners as indicated.
Install the fasteners as indicated.
- or Flow Form Rivets, S28
- or Flow Form Rivets, S38
Install the fasteners as indicated.
- or Flow Form Rivets, S28
- or Flow Form Rivets, S48
Install the fasteners as indicated.
- or Flow Form Rivets, S18
- or Flow Form Rivets, S28
- or Flow Form Rivets, S48
Perform any necessary post-repair operations.