Model S Body Repair Procedures

[NiallDarwin]

Hi,

I bought a smashed 2016 Tesla S 90D in Sydney, Australia with the intention of repairing it and getting it on the road here in New Zealand.

Fixing what I call the 'important' issues is easy. A new rear right set of suspension is soon to be bolted on then the car will be driveable once more.

I'm struggling to get what I considered the 'superficial' body damage repaired. The authorised body repairer in Sydney is busy and unhelpful. There isn't an authorised repairer in NZ yet. I have found a helpful company with Aluminium vehicle specialisation fairly close to me. They need the Tesla repair procedures. I am waiting on callbacks from Tesla workshop and parts people to see if I can get this information and prices for the body parts. I'm not holding my breath.

If any of you could lay your hands on repair procedures I would be very grateful. I am also interested in anyone with experience in putting used panels on to a car. It seems from what I've read as though this isn't possible but it goes against a lot of what I know.

Thanks,
Niall

 

[mblakele]

So you're trying to repair body panels instead of replacing them? As I understand it Tesla prefers replacement.

 

[jelloslug]

Refreshed body or classic body?

 

[NiallDarwin]

jelloslug: Refreshed body

mblakele: I am trying to repair the car to a high standard. I need the Tesla repair procedures to understand how to do the repair. If it needs new parts that is what it will get. If it does not then it won't. Until I have the information it is pointless guessing. I am frustrated at the difficulty in obtaining this critical information.

 

[MP3Mike]

Have you visited the Tesla service site: https://service.teslamotors.com/

They have some information there:

• Safety and approved fasteners/adhesives: https://service.teslamotors.com/important-safety-information
• Body repair operating standards: https://service.teslamotors.com/sit...pair_Program_Operating_Standards_20170419.pdf
• A flyer on their body repair training program: https://service.teslamotors.com/sit...-info/Training_Overview_Brochure_20170504.pdf

I think you can email [email protected] to find out about their training program: Bridge.

 

[Tesmotorfaqcom]

I believe you can rent the tesla service manual for a cost as certain states in US require this information to be make available but the cost is high

 

[jelloslug]

jelloslug: Refreshed body

mblakele: I am trying to repair the car to a high standard. I need the Tesla repair procedures to understand how to do the repair. If it needs new parts that is what it will get. If it does not then it won't. Until I have the information it is pointless guessing. I am frustrated at the difficulty in obtaining this critical information.

Tesla does not recommend repairing any body panels, only replacing them.

 

[NiallDarwin]

MP3 Mike: Thanks for the tips. I don't think the shops I'm dealing with are wanting to jump through the hoops to become certified. They just want the procedures. Which rivet goes where etc. I'll show them the links, I may be wrong

Tesmotorfaqcom: Thanks. I have the service manual. It does not cover body repairs.

Jelloslug: Thanks. That's already been stated and as I said in the post you quoted I am going to follow their procedures not guesses.

 

[appleguru]

Where did you get a service manual for the AP2 model s? Been looking for one forever...

 

[appleguru]

You should be able to get them from https://service.teslamotors.com

(At least, I can... Not cheap at $30/hour for access though I do live in MA in the US however, so that may have something to do with it).

They have "Body Repair Tech Notes" (which include things like approved fasteners, adhesives, benches, welders, etc), as well as body repair instructions for each part of the model S.

There are also some service bulletins that cover paint.

 

[NiallDarwin]

Appleguru, that's very very very interesting. Thank you.

Sorry for my lack of knowledge but when you say "AP2" do you mean the recent facelift or something else? My manual came from a user here, artsci. Its for the non-facelift model but the changes (I believe) are minimal.

 

[mblakele]

when you say "AP2" do you mean the recent facelift or something else?

AP2 is usually shorthand for AP HW2, the latest camera hardware with new cameras in the B pillars and side repeaters which started shipping in November. You'd probably have noticed if your salvage 90D has HW2: more likely it is an original AP HW1 config.

The HW2 components might affect some body work, but mostly fishing more wires around I'd think.

 

[NiallDarwin]

Gotcha. AP = AutoPilot HW = HardWare?

I haven't noticed those cameras. My car is still on the other side of the Tasman Sea to me so it's not easy to take a closer look

 

[mblakele]

Gotcha. AP = AutoPilot HW = HardWare?

I haven't noticed those cameras. My car is still on the other side of the Tasman Sea to me so it's not easy to take a closer look

Yes, HW = hardware.

If you have any side photos the difference should be obvious, at least when you know what to look for. The side repeater sticks out, and the B pillar is often visible. Or a good photo of the front might show the camera housing in enough detail.

For example this random image is HW2: I can see the camera in the B pillar. The repeater seems to stick out too, but it's a low-quality image so I wouldn't be sure without the B pillar.

This one looks like HW1, based on the camera housing, flatter repeater, and lack of B pillar camera:

 

[NiallDarwin]

Mine's AP2 I think:
Photos - Google Drive
Doesn't get me closer to a repair but it does mean the car's worth more than I'd thought!

 

[Dborn]

Can't see the side marker light which would be definitive in your photo. Why won't the authorized repairer take it on? Busy or not.

 

[mblakele]

Can't see the side marker light which would be definitive in your photo

It's HW2: the B-pillar camera is visible in a couple of those photos.

 

[NiallDarwin]

I am authourising repairs to my damaged 2016 Model S and I require repair plans for the rear ¾ panel. The car is at a very well equipped panelshop with factory certification for many types of aluminium bodied vehicles but not yet Tesla.

It is not practical to get the car to an authourised shop-there are only two in the whole of Australia and both are extremely busy.

I would like the repair plans for this job so that my body shop can do the job correctly. If you can provide the information please get in touch. Openly here, via PM or my email which is nialldarwin at gmail

Thanks and potentially reward will be given.