Welcome back to the channel! This week’s video is the continuation of the Tesla Model 3 with rear end structural repairs. If you missed the first part, I highly recommend you check it out before diving into this one. The link is in the upper right-hand corner along with the subscribe button so you don’t miss any new episodes every Friday.
In the previous video, we saw all the structural damage being cut off and the vehicle being test-fitted. Now, we’re moving on to disassembling the rear bumper cover and all five bumper retainers. The select jigs are built back together before removing, as we had to remove the lower half to test fit our rear bumper cover. Once the floor and three rail pieces are removed, all the remaining structural adhesive is cleaned off the mating flanges on the rail before test fitting and mounting them to the select jigs.
With the rail pieces tested on the select jigs, we start drilling all the rivet holes for the rail brackets. These rail brackets will be rivet bonded using 6.5 structural rivets with structural adhesive. Next, we drill all the holes for the rail end plate, which will be attached with 6.5 structural countersunk rivets and structural adhesive. The holes need to be countersunk with a special drill bit to ensure the rivets sit flush on the end plate.
After drilling all the rivet holes for the rail pieces, we realize we missed removing the side floor extension. This piece needs to be removed to allow access for the rivet gun for the rail pieces. All the spot welds are ground down using a belt sander, the panel is warmed up to release the structural glue, and then removed.
The rail pieces are prepped for structural glue, which is then applied on all the mating flanges. The rail end plate and brackets are fitted, and all the rivets are installed. The structural glue is left to dry for 24 hours before testing the floor. The rivet locations are mapped out, drilled, and the floor is prepped to match the original.
The floor extension is clamped into place, holes are drilled for the rivets, and then prepped for structural adhesive. The floor extension is attached to the body, and the floor is prepped for structural adhesive before being dropped into place and all the 6.5 mil rivets are installed.
This week’s video is now complete, but make sure to subscribe and stay tuned for next week when we finish the structural repairs. Thanks for watching!
