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.
Quantity Part Number Description Image / Notes
23 rivets or 62
riv
ets needed;
order 30 rivets or
70 rivets
1028408-00-A
Structural Rivet, 6.5 mm Short
All rivets come in packages of 10; order all rivets
in multiples of 10.
23 riv
ets are needed if the lower flange of the
new Sill Outer front section can be attached to
the Sill Inner with resistance spot welds.
62 rivets are needed if the lower flange of the
new Sill Outer front section cannot be attached
to the Sill Inner with resistance spot welds.
18 rivets needed;
order 20 rivets
1454538-00-A
High Strength Structural Rivet,
6.5 mm
All rivets come in packages of 10; order all rivets
in multiples of 10.
9 rivets needed;
or
der 10 rivets
1069327-00-A
Structural Countersunk Rivet,
6.5 mm
All rivets come in packages of 10; order all rivets
in multiples of 10.
1 — Structural Adhesive
WARNING: Use only T
esla-approved
structural adhesive; refer to BR-15-92-008,
"Approved Structural Adhesive and
Urethane Sealants" for a list of current
approved structural adhesives.
Refer to BR-17-92-002, "Obtaining Adhesives,
Coolant, and Other Chemicals" for information on
how to obtain approved structural adhesive.
1 — Weld-Through Primer Source locally; not available from Tesla.
1 — Corrosion-Resistant Epoxy Primer Source locally; not available from Tesla.
1 — Seam Sealer Source locally; not available from Tesla.
These part numbers were current at the time of publication. Use the revisions listed or later, unless otherwise specified in the
P
arts Manual.
Sill Outer (Front Section)
Parts List
TESLA BODY REPAIR MANUAL
F
or feedback on the accuracy of this document, email BodyRepair@tesla.com.
Updated: 09APR18 3