User Manual
Table Of Contents
- Sill Outer (Front Section)
- Parts List
- Repair Information
- Prerequisites
- Removal
- Replacement
- Prepare the new Sill Outer front section.
- Create a reinforcement plate for the new Sill Outer front section.
- Prepare for installation of the new Sill Outer front section.
- Prepare the surfaces to install the new Sill Outer front section.
- Apply structural adhesive to install the new Sill Outer front section.
- Install the new Sill Outer front section.
- Prepare a backing plate for the installation of the new Hinge Pillar se
- Prepare for installation of the new Hinge Pillar section.
- Prepare the surfaces to install the new Hinge Pillar Assembly section.
- Apply structural adhesive to install the new Hinge Pillar Assembly sect
- Install the new Hinge Pillar Assembly section.
- Prime any bare metal that will not be covered with weld-through primer
- Prepare the new Body Side Outer section for installation.
- Create and install backing plates for the Body Side Outer butt joints.
- Prepare for the installation of the new Body Side Outer section.
- Prepare the surfaces to install the new Body Side Outer Section.
- Apply structural adhesive to install the new Body Side Outer section.
- Install the new Body Side Outer section.
- GMA weld the Body Side Outer butt joints.
- Secure the butt joint flanges.
- If required, apply a suitable body filler to the joints and finish for
- Prime any bare metal with a suitable corrosion-resistant epoxy primer.
- Seal the seams in the factory locations, and as necessa
- After refinishing, use a 360-degree spray wand of suitable length to ap
- Install the new Shotgun Outer.
3
Prepare for installation of the new Sill Outer front section (continued).
D
Use a drill with a 6.7 mm (17/64 in) bit t
o drill holes for structural
rivets through the holes in the template, and then remove the
template (continued).
E
Mark the r
emaining fastener locations on the new Sill Outer (front
section) and the reinforcement plate.
Structural Rivet, 6.5 mm Short (x19)
Installation Spot Weld (x24)
NOTE: If the HV ba
ttery is out of the vehicle, or if the resistance spot
welder being used can access the lower flange area, spot weld along
the lower flange in the factory spot weld locations. Otherwise the
lower flange area of the new Sill Outer front section will be secured
with structural adhesive, and then structural rivets will be installed in
these locations during the installation of the Body Side Outer
section.
Sill Outer (Front Section)
Replacement
TESLA BODY REPAIR MANUAL
F
or feedback on the accuracy of this document, email BodyRepair@tesla.com.
Updated: 09APR18 29