Tesla Model Y Texas-Built Giga Castings Removed!

[hridge2020]

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[CyberGus]

The torch was a nice touch.

 

[rr6013]

Interesting…MY

• Front casting 185#
• Rear casting 165#
• Steel front shock tower fish plate reinforced
• Serviceable mounting extensions bolted onto casting
• Integrated McPherson upper strut mount
• Rear casting non-removable, unserviceable
• Chemical bond superiority over mechanical and welded

Castings will “Total” a car for insurance settlement purposes should they be damaged. BUT BodyShops have long repaired cars using the rear or front clip method. Clip method cuts a Donor car in half. Replacing the damaged half with the Donar car clip(frt or rr). SO its not like Teslas are going to be crushed, junked and raise insurance costs. There’s much benefit to be gained by castings. Weight savings are impressive, structural rigidity improves but assembly, production and manufacture cost savings are ginormous.
And the repairability is there for castings albeit by front or rear clip from Donor car method.

 

[firsttruck]

....
Castings will “Total” a car for insurance settlement purposes should they be damaged. BUT BodyShops have long repaired cars using the rear or front clip method. Clip method cuts a Donor car in half. Replacing the damaged half with the Donar car clip(frt or rr). SO its not like Teslas are going to be crushed, junked and raise insurance costs. There’s much benefit to be gained by castings. Weight savings are impressive, structural rigidity improves but assembly, production and manufacture cost savings are ginormous.
And the repairability is there for castings albeit by front or rear clip from Donor car method.

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In general, even cars that do not use front casting or rear casting are no longer repaired using clip (sectioning) method. Clip method for repair was probably more common before 1978 when government started crash testing cars.

Using clip (sectioning) method is illegal in some states or would require a new title that would warn and subsequent buyer of the repair. Some insurance companies might refuse to insure a clip (sectioning) method repaired vehicle because is another accident occurred the vehicle occupants might believe they suffered higher injuries because vehicle did not protect them enough and sue the insurance company. Does the body repair shop want the extra risk of being sued when the auto manufacturer advised against that method of repair.


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NHTSA and IIHS Crash Test Safety Ratings Explained
By Nick Kurczewski
Feb 27, 2021
https://www.caranddriver.com/featur...-about-the-wrecks-behind-the-ratings-feature/

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NHTSA's Stars on Cars NHTSA started wrecking cars in 1978 to test their performance during frontal-impact crashes and later added side and rollover crash tests as well as lists of recommended safety technology to its New Car Assessment Program (NCAP). Ratings are given for each test as well as overall, with five stars being the top score. The federal agency now conducts 90 to 125 tests annually on high-volume models that are new or significantly updated for a given model year.


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To Clip or Not to Clip? “What’s the difference among what I-CAR, shops, insurance companies and car manufacturers are saying about clipping?”
By Paul Bailey on April 1, 2007
https://www.bodyshopbusiness.com/to-clip-or-not-to-clip/

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What the OEMs Say What do manufacturers have to say? Some have bulletins that may be obtainable through your local dealer or you can check their technical information Web sites. For instance, Toyota’s Collision Repair Information Bulletin (CRIB) #122 states, “Full body sectioning, also known as clipping, is not an approved repair procedure on any Toyota or Lexus vehicle. Full body sectioning is generally done on a vehicle that has sustained severe rear end damage, where the front portion of one vehicle is joined with the rear portion of another vehicle.”

Other manufacturers have issued position statements, and some are quite clear in their disapproval of the use of this repair method. In a General Motors statement released November 1, 2006, Pamela Reynolds states, “Replacing damaged parts of a vehicle designed to crush in a collision may reduce occupant protection in a future collision. GM has not tested or validated a clipped vehicle repair, therefore, GM cannot endorse this type of repair or confirm the crash performance in a subsequent collision.”
Ford Motor Company’s Steve Nantau is also clear in a detailed statement against clipping in which he brings up several important issues the repairer should consider. “Because every repair is unique, it is impossible to test whether the repair technique affects the safety, performance or durability of the vehicle. Other factors weigh heavily in this position, including hidden damage to individual components, assemblies or systems in the clip that may not be readily apparent to the repairer.”

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All of the manufacturers are clear in pointing out that salvage parts are not covered under the vehicle’s warranty. They also clearly explain that if the vehicle sustains damage or corrosion that resulted from a problem with the salvage part, the vehicle warranty won’t cover it. The OEMs don’t cover their own product when it comes from a salvage yard because of its unknown history and variables such as previous damage and exposure to elements. New, undamaged parts that are properly installed will react to a subsequent impact in the same manner as the original parts.

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Ford’s Nantau also points out the importance of legal issues to consider. “Ford strongly recommends that repairers and insurers considering the use of a clip carefully check state collision repair laws and regulations to determine whether the vehicle must be re-titled as ‘rebuilt’ or ‘salvage’ if the clip procedure is used,” he says. “Ford also strongly recommends that repairers advise and obtain the written repair authorization of the vehicle owner, in advance, if the clip procedure is to be used and re-titling is required.” Against the Law? I checked through some different states’ statutes and found that several other states have something written into their laws worded similarly to this Florida statute:

559.920 Unlawful acts and practices. It shall be a violation of this act for any motor vehicle repair shop or employee thereof to: … …(16) Rebuild or restore a rebuilt vehicle without the knowledge of the owner in such a manner that it does not conform to the original vehicle manufacturer’s established repair procedures or specifications and allowable tolerances for the particular model and year.


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[firsttruck]

Full body sectioning or 'CLIPPING'
By Al Thomas
Jan. 1, 2020
https://www.vehicleservicepros.com/...cle/21167474/full-body-sectioning-or-clipping

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To begin with, no vehicle manufacturers endorse clipping as a repair method. In fact, in a recent Toyota article, one of their collision repair instructors, James Myer, stated, "While clipping may seem to be a convenient shortcut, it can significantly decrease the quality and safety of the vehicle, and be responsible for negative customer satisfaction .... potential problems include poor fit and body alignment, squeaks and rattles, wind noise, water leaks and diminished resistance to rust and corrosion."
Ford Motor Company information released in 2005 stated: "Ford Motor Company does not approve the use of 'clips' to repair collision damage to vehicles." The document warns that when a vehicle is clipped it "voids the Ford's new vehicle limited warranty and extended service plan."

And during last month's NACE show, ABRN discussed clipping with representatives from General Motors. GM does not approve of the practice and echoed Ford's position on warranties. Clipping voids GM's new vehicle limited warranty, any variety of the GM Protection Plan, as well as GM's new vehicle service part and corrosion warranties for each part in the clip, the automaker states.

While other manufacturers also have statements against sectioning, some do not address the procedure.

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Remember also that should you head down this repair path you must take into consideration differing state laws concerning VIN numbers and branded titles. Finding a donor and then measuring and restoring both halves to the vehicle's pre-accident condition can be difficult. In addition, not all technicians who attempt the procedure are capable of completing it without misalignment, leaks, or questionable welds occurring.

 

[charliemagpie]

I had something to do with a large repair shop... around 80 repairs a week.

I never saw that type of repair.

 

[TyPope]

Interesting…MY

• Front casting 185#
• Rear casting 165#
• Steel front shock tower fish plate reinforced
• Serviceable mounting extensions bolted onto casting
• Integrated McPherson upper strut mount
• Rear casting non-removable, unserviceable
• Chemical bond superiority over mechanical and welded

Castings will “Total” a car for insurance settlement purposes should they be damaged. BUT BodyShops have long repaired cars using the rear or front clip method. Clip method cuts a Donor car in half. Replacing the damaged half with the Donar car clip(frt or rr). SO its not like Teslas are going to be crushed, junked and raise insurance costs. There’s much benefit to be gained by castings. Weight savings are impressive, structural rigidity improves but assembly, production and manufacture cost savings are ginormous.
And the repairability is there for castings albeit by front or rear clip from Donor car method.

Don't forget the quality of the cars goes up tremendously as the panel gaps can be made to perfectly fit. There will no longer be minor variations due to metal temp during/after welding, adhesive inconsistency, and others. Those castings will always be the same. You'll see panel gaps and overall quality go up on these...

 

[rr6013]

I had something to do with a large repair shop... around 80 repairs a week.

I never saw that type of repair.

In the Midwest, I sold a front or rear clip every other month. My college car was a brand new ‘71 Monte Carlo proudly sporting a rear bumper smashed against its backseat. Found a rear clip in DENver 900miles away and welded the two together in time for Semester start.

Clip method is a pretty slick solution cutting across the roof and bottom floorpan at the door opening. The front clip ditto…except it cuts through the A-pillars .v. roof so the windshield fitment glue-in affords a margin to fill any gapping. Welds are stronger than extrusions are stronger than sheetmetal.
Cybertruck glass roof is golden affords margin to spare on front and rear clips. Total shop time 2 wk. + paint.

 

[FutureBoy]

In the Midwest, I sold a front or rear clip every other month. My college car was a brand new ‘71 Monte Carlo proudly sporting a rear bumper smashed against its backseat. Found a rear clip in DENver 900miles away and welded the two together in time for Semester start.

Clip method is a pretty slick solution cutting across the roof and bottom floorpan at the door opening. The front clip ditto…except it cuts through the A-pillars .v. roof so the windshield fitment glue-in affords a margin to fill any gapping. Welds are stronger than extrusions are stronger than sheetmetal.
Cybertruck glass roof is golden affords margin to spare on front and rear clips. Total shop time 2 wk. + paint.

What about the structural battery pack? The clip you describe would seem to cut the battery pack directly in half. Not sure that would be a good idea.

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