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.
9
Prepare the surfaces to install the new Hinge Pillar Assembly section
(c
ontinued).
C
Use a disc sander with a medium-abrasive surface conditioning disc
to remove the e-coat in the weld areas.
WARNING: R
emove the e-coat in a well-ventilated area. Wear
suitable personal protective equipment.
CAUTION: Take the appropriate steps to minimize the cross-
contamination of steel and aluminum components during the repair.
NOTE: Use a belt sander with a medium-abr
asive belt for any areas
that cannot be reached with a disc sander.
D
Clean all the bond pa
ths and weld areas on the new section, the
reinforcement, the backing plate, and the vehicle with isopropyl
alcohol (IPA).
WARNING: W
ipe o 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.
Sill Outer (Front Section)
Replacement
TESLA BODY REPAIR MANUAL
F
or feedback on the accuracy of this document, email BodyRepair@tesla.com.
Updated: 09APR18 76