Plastic trim (roof applique) bowing

[j0e_Jitsu]

I have issues with the roof applique bowing up when it's hot out. Anybody else have this problem? I read the service manual but it doesn't tell you how to pop it out. It just says " Release the clips (x5) that attach the LH roof applique to the vehicle, and then remove the applique from the vehicle. "

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[TheEternalShore]

Yeah, I was going to post about this yesterday, but didn’t get around to it. It was the hottest day of the year so far and I noticed the same bowing on that trim piece on mine. I got up there and poked and pulled at it and it didn’t seem like it was going to let loose, but definitely shouldn’t be bowing like that. I think Tesla needs to look at using a different kind of plastic there. All the textured plastic pieces seem to handle the heat fine. Those glossy pieces do not.

It looks like it would be an easy piece to replace with stainless or aluminum, so if any after market companies want to look into that, then there might be a market there.

 

[Dazureus]

I saw some Facebook posts (possibly FUD) complaining about the roof mount doors melting/warping unexpectedly and became interested in the plastic composition. I'm not sure if cover plates are the same composition as the appliques, but the matte materials are marked as ASA (acrylic styrene acrylonitrile) with a glass transition temperature of 100C and the glossy materials (Tesla calls this Molten Black) is labeled as PMMA (polymethyl methacrylate) with a glass transition temp of 102C. It makes me a little suspicious about the melting plastic posts, unless the plastics aren't being manufactured to Tesla spec. Both plastics have a relatively high coefficient of thermal expansion so either the clip placement in the appliques don't allow for enough expansion (engineering) or the clips themselves are too pliable or not seated correctly and are releasing (manufacturing). I'm leaning towards the latter since we've seen some other instances of both these appliques disassembling while driving.

I've been paranoid about pressing on the clips to ensure they're well seated. Are you able to press down on the applique to reseat the part?

 

[j0e_Jitsu]

I saw some Facebook posts (possibly FUD) complaining about the roof mount doors melting/warping unexpectedly and became interested in the plastic composition. I'm not sure if cover plates are the same composition as the appliques, but the matte materials are marked as ASA (acrylic styrene acrylonitrile) with a glass transition temperature of 100C and the glossy materials (Tesla calls this Molten Black) is labeled as PMMA (polymethyl methacrylate) with a glass transition temp of 102C. It makes me a little suspicious about the melting plastic posts, unless the plastics aren't being manufactured to Tesla spec. Both plastics have a relatively high coefficient of thermal expansion so either the clip placement in the appliques don't allow for enough expansion (engineering) or the clips themselves are too pliable or not seated correctly and are releasing (manufacturing). I'm leaning towards the latter since we've seen some other instances of both these appliques disassembling while driving.

I've been paranoid about pressing on the clips to ensure they're well seated. Are you able to press down on the applique to reseat the part?

I'm able to push down on it and they feel like they are properly seated. It bows out the most near where the cross bars would be mounted.

 

[panthar]

I have issues with the roof applique bowing up when it's hot out. Anybody else have this problem? I read the service manual but it doesn't tell you how to pop it out. It just says " Release the clips (x5) that attach the LH roof applique to the vehicle, and then remove the applique from the vehicle. "

It seems some click plastic trim piece below the surface popped up either due to heat or something ...
climb into the bed and try to pry little bit and see what is below it ... it might be a just a knock or blow would make it settle down ...

if u cant reach it take a ladder and place it near door side and climb up to have a good look ...

 

[Dazureus]

Looks like there are 5 clips on the roof applique and yes, they bridge the roof rack hold down points.

They looks like they mate with the sides of the rectangular clips, but it's difficult to tell if it allows any expansion of the applique along it's length.

Coefficient of thermal expansion for PMMA is at worst 9x10-5mm/C so total expansion along the length "should" be small for even hot ambient temperatures, but the clip design might be locking down linear expansion tolerance, as exhibited by your vehicle. Might be worth it to pop the whole applique off and reseat it to see if there's some variability of placement that lets it sit flat, or at least see if the clip design allows it to slide a little when it heats up, but is binding in your particular installation.

 

[aeroguy]

I saw this during the first really hot day after taking delivery last month. The plastic wasn’t melting or warping, it just appeared bound up from either the clips or the positioning being too close to the rear stop. Either way, popping the trim out and reseating seemed to alleviate the problem.

 

[j0e_Jitsu]

I saw this during the first really hot day after taking delivery last month. The plastic wasn’t melting or warping, it just appeared bound up from either the clips or the positioning being too close to the rear stop. Either way, popping the trim out and reseating seemed to alleviate the problem.

So how do you pop it out do I just pull up on or is there a certain way to pop it out?

 

[aeroguy]

So how do you pop it out do I just pull up on or is there a certain way to pop it out?

You could use a plastic trim tool…but I opened the roof rack attachment point cover and gently lifted until I could get enough leverage to pop up one side of one clip (inboard side). Then work your way down the inboard side until all 5 are free.

 

[j0e_Jitsu]

You could use a plastic trim tool…but I opened the roof rack attachment point cover and gently lifted until I could get enough leverage to pop up one side of one clip (inboard side). Then work your way down the inboard side until all 5 are free.

I did just that thank you I reseated it. I looks better than it was.

UPDATE: It didn't help, the sun just heated it up again a started bowing

 

[j0e_Jitsu]

I wonder if adding a flat carbon rod in the plastic trims channel will help keep it rigid and prevent it from bowing so much.

 

[Stuck4ger]

I have issues with the roof applique bowing up when it's hot out. Anybody else have this problem? I read the service manual but it doesn't tell you how to pop it out. It just says " Release the clips (x5) that attach the LH roof applique to the vehicle, and then remove the applique from the vehicle. "

I went by the Merritt Island SC yesterday and there were 3 AWD and 1 Beast in front. The AWDs looked fine but the beast had that issue. I pushed down on the right side and it clicked back into place but the left side felt like a plastic spring. I went inside and pointed it out to the sales rep and he acted like he was aware and it would be addressed. I didn’t look at the AWD manufacturing dates or VINs.

 

[DrPhyzx]

Yep, classic thermal expansion mismatch problem. It only takes a very small change in length - a fraction of a mm - to create a pretty large bow in this way. If the clip design is too constraining, it's a bad design and will need to be changed.

 

[j0e_Jitsu]

I went by the Merritt Island SC yesterday and there were 3 AWD and 1 Beast in front. The AWDs looked fine but the beast had that issue. I pushed down on the right side and it clicked back into place but the left side felt like a plastic spring. I went inside and pointed it out to the sales rep and he acted like he was aware and it would be addressed. I didn’t look at the AWD manufacturing dates or VINs.

I do have the beast it's interesting that you mentioned that it affects the beast more than the AWD

 

[Spacenoddle]

Seem like one or more of 5 clips didn't seated correctly during the assembly.

i always amazed about how variable of the craftsmanship in the Tesla factory. It might be the price to pay during the rampup.

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