Tesla Model Y GIGACast Repair
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- เผยแพร่เมื่อ 31 ธ.ค. 2022
- Tesla Model Y GIGACast Aluminium Diecast repair. This is one of our Salvage title donor model Y that had been involved in a front end collision. The fender support bracket has been snapped off, so I attempt to weld it back together to see the practicality of repairing the GIGACast.
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You should use 4047 wire. The silicon content of the 380 die cast alloy is 7.5 to 9.5%. It's a better match for strength and shrinkage properties. The 5000 series has a tendency to crack during solidification since it shrinks more than the higher silicon alloys. Also be aware that high pressure die cast aluminum can contain small pockets of high pressure nitrogen gas. Air sometimes gets trapped in the metal if dies are not properly venting the enclosed air as the metal is injected. The air in the die can get surrounded and trapped by the incoming injected metal. The 21% oxygen reacts with the aluminum to form a solid but the 79% nitrogen remains as a high pressure gas pocket. Any blowouts however just need to be repaired. There is no reason that repair welding will not work, especially in lightly loaded areas such as the fender support area as long as attaching parts are in proper position. Good luck and keep up the good work.
Excellent advise, Ill get some 4047 to try. Thanks!
Damn - are you like, a doctor of aluminumology....? 😉
I had no idea of all that, lol.
It's an AI bot...
AFAIK, Tesla draw a vacuum in the die before injecting, so there shouldn't be many gas pockets.
@@pawpatrolnews Using 40-series filler is an established casting repair method. Nothing in that post is beyond what an experienced TIG welder who works on cast aluminum wouldn't know off the top of their head. Casting repair is a moneymaker especially in the marine and powersports industries.
Glad a Tesla has a shot at being repaired. Crumple zones for safety vs cost vs second life. Yeah, a lot of difficulty balancing those.
Giga casts are about cost. That's it.
En France cette voiture va directement à la destruction elle ne passerais jamais les contrôles techniques !!
@@truantray That is wrong, it is about quality work done fast and at less cost.
@@truantray do they make it easier for better panel fit, less gap variation? This expected by some to feed the narrative “Elon has mastered manufacturing - Tesla’s new competitive advantage”
Tesla, good job welding! I also work at Austin plant. We only have the prototypes and of course there will be many problems to fix. I am very confident that they will work it out. They always look at other technicians that are repairing their products to adapt the current manufacturing processes. Thank you for letting us know the manufacturing defects we currently have with them on our way.
One thing for certain, Tesla never stands still.
Tesla. First watching someone fix a gigacast. Nice work.
Tesla
So good to see its not impossible to weld!!
Wow, disposable cars if more than a minor fender bender, holy sh1t!
Tesla! Thanks for being on the edge. I am sure tesla will hear the feedback and will incorporate it into their future revisions
TESLA: I would love to see more Giga cast repairs. Maybe more major structural repairs.
Rivian. Sandy Munro noted that the first series of castings were designed to use up leftover parts, so there were a lot of weird brackets and weldments that don’t make sense at first. Supposedly the plan was to have new castings made that the rest of the car fits around rather than having the casting fit the car.
Tesla. Totally agree with your comment about the repair ability of the bracket. Seems that they could eliminate the wing completely and tie the sheet metal into the diagonal holes in the receiver part of the casting.
So everyone is going to re-engineer the Tesla?
I shared your video to the Tesla community on Twitter. Thank you for the great work!
Awesome thank you!
Tesla. This needs more exposure than the by chance appearance in my feed. Sandy Munroe might want to look at/comment on this. Brings up an important point about the repairability of the gigacasting. Great vid. Thanks for sharing.
I would enjoy getting the attention of Sandy! We could have lots to chat about no doubt.
Sandy isn't going to criticize Tesla...he practically made his channel off WORSHIPPING them. Also remember, Munro was the guy who told Ford back during the Fiesta days that using cast frame and suspension parts was a STUPID idea.
You don't need him running interference for what was truly a newbie mistake by Tesla. Especially since they've spent so much time and buzz BRAGGING about it.
@@billcichoke2534 Sandy will criticize anyone he thinks needs it.
@@scottgaree7667 Except companies he's still invested in.
Very interesting, ..once had to weld the Aluminium trailing arm of a planter, and hadn't thought about the castings getting damaged like this. The plan is to take advantage of 1:8 or more reduction of collisions, whatever the Insurance stat's comes to nowadays, but the weld job is first principles consideration for getting repairs done and avoiding the usual run around.
Thanks for the demo.
Tesla. I have no idea how this vid came across my eyes, but it did so something is working. subscribed. :)
Thanks! Appreciate it
Thank you for watching and leave in comments
TESLA, mate!
And….good work!
..and a good video!
I like it, when things are not unnecessarily stretched, and this isn‘t. Oh, good music.
Much appreciated!
Yeah, it's going to be interesting to see how the gigacastings fair in the next 3 to 5 years, especially as it pertains to insurability. If minor fender-benders are resulting in a large percentage of totaled vehicles I wouldn't be surprised if many insurance companies just start refusing to insure the ones with gigacasting.
I was going to comment the same 👍👍
If you search for the article title "Crashed Teslas With Low Mileage Are Being Scrapped Because They’re Too Expensive to Fix Robb Report" (leave the quotes off) you'll see some comments from Elon Musk & how some design changes need to be made.
@@softwaresignals thank you very much for the information 👍
So you are saying that the insurance companies are going to refuse to insure the worlds safest car? That just leaves more money for Tesla insurance to make.
@@tedmoss Well, it may be the world's safest car, but they still do get into accidents. And when they do, if they have this difficult to repair gigacasting then insurance companies _may_ either have extremely high premiums or decide it's not worth the risk and refuse to insure them at all. But, I'm sure at this point many insurance companies are keeping a close eye on this to see how it goes over the next few years. Maybe Tesla can mop up the people rejected by mainstream insurance?
I've seen repair diagrams from Tesla which show surprisingly large areas of the casting that can be repaired.
Thanking you for the video , Tesla. Constant refinement is a way of life, efficient design and equally , as you suggest an efficient repair is wisdom.
Tesla. Good to see the GigaCast and your thoughts on repairability. Its a really interesting, very rigid, nearly perfect every time frame from what I have read, but yea repairability... Thanks for the video.
hi yes I agree with you any flanges sticking out of a casting will not bend just snap of,
they could easily be sheet aluminum bolted on so they can be removed and straighten or replaced, its not really structural its a bracket,
All the flanges sticks out of that bracket cut $100s of the cost of assembling the car.
The TH-cam Channel "The Limiting Factor" had a video about the giga casting that listed the elemental ratios Tesla is using. Looked more like a 2000 series aluminum with a custom mix to reduce copper content.
Hey. TESLA. Your videos are interesting to the car people I don’t see why they wouldn’t stick around to watch till the end. Keep some more videos coming and see how it turns out 👍🏻👍🏻
I really liked this video on Tesla's Model X giga cast repair...I was very curious about its repairability, so thanks. Cheers to the 30% who stayed on.
Tesla! Fascinating, thanks for showing how it can be fixed. I'm sure many DIY'ers would at least love to have a chance to tackle a potential fix of a broken Tesla.
Tesla. No wonder the insurance on those things is so high. Very interesting to see the inside of the fender well. Y’s perform very well in partial front crashes I can see why.
I pay 768 every 6 months for my wife and I. 2021 Model Y in So Cal
Insurance is not high anymore. Texas Farm Bureau insures our Tesla for less than my Colorado. Yes, we haul in the crops with the Tesla. ;-) Just kidding.
I didn't even know that was possible. Super cool.
Tesla
First time seeing this type of repair. Thanks for sharing 👍
Nice Tesla welding. Good comments on repair and design changes.
TESLA. I'd love to see more of what you do and around your shop! It's also great to see you are located nearby in Guelph.
I’m always around if you want to see the shop!
TESLA
Made it to the end!
Really interesting video I have been curious about this for a while now.
Thanks for posting
I also subscribed!
Tesla
Reassuring stuff from a very competent and logical TH-camr. Really impressed.
Subscriber from France 😊
Thanks and welcome
ABC of welding: I like that and will bare it in mind! Great film thank you.
Nice repair and thanks for posting the video. I wanted to make a suggestion to make your sign on the wall just a bit cooler. Paint the outline of the 519 off your shirt on the wall behind the sign, it will pop real nice, plus the color off your shirt is in the same pallete as the color on the wall. I think it would look so cool.
I'm impressed by the way you were able to weld the aluminum alloy of the TESLA gigacasting. Good job. My dad wears a Large. He tried to comment on the TV but he has no app on his phone, Don't ask! Anyway. Keep up with the good work and videos.
Awesome thanks. Appreciate it!
Good job, thank for the time to video your procedure
.
Tesla. Thanks for doing this. I'd like to learn to weld like that. Yes I'm interested in other projects.
Telsa - Wish I could weld half as good as that.
I her that
I forgot how to spell man I’m dumb
Tesla! Wanted to see if was possible to repair a casting! Thank you for sharing.
FYI i skipped through the video and watched the conclusion. Interesting stuff thanks for putting this information and your thoughts out there
Tesla is as Tesla does. Thanks for the content! Accidents never happen in a perfect world 🌎
Tesla. Enjoyed your video, well done with your calm, clear voice, the clever camera angles, and the mellow music. Wish you success.
Thank you so much!
If i might give some input here. Companys do not like extra parts. Companys are not interested in designing in a way that makes parts repairable. I am honestly surprised that they didn't incorporate the stamped piece into the casting. That would have saved a lot of money/time. The way the part is shaped also tells me that they are doing two things with this part.
1. Take up force from up and down.
2. Stiffening the frame part.
This part might also be shaped like this so that it does shear in a front crash. I don't know too much about that.
If I may give an advice here. Sell a repair set where you basically replace the feature with a screw in holder. You would have to invest a lot of time into making it perfect (different materials, manufacturing, fixture for assembly) but you could sell it for whatever you want. The costumer will pay whatever if it fixes his problem.
I like that suggestion, I have actually done a bit of cad work in my spare time to make a different bracket.
tesla. I realize the swag must have already been awarded. just adding my presence for the analytics feedback. the subject was interesting to me as a tesla owner.
Tesla
The algo popped your video up. Glad it did. Looks like you have some nice custom work.
Always lots of custom stuff going on. More videos to come!!
Enjoyed good luck making videos
Tesla! I know it’s a month old but still wanted to let you know. Loved the detail. Was on verge of buying 4680 and this is good info on probable concerns with simple fender bender.
Thanks, appreciate you!
Passing the costs to insurance then customer! Musk way! I’m just hoping that others will not follow
Tesla~ I can see an industry of aftermarket bolt on repair kits. Maybe even out of FRP. Where you'll grind and cut a piece then drill and bolt on the non-critical support.
The entire industry is about reducing fasteners.
We've learned how to weld/melt plastic components back together. This is just the next evolution in repairs.
Pretty good info being able to weld the Tesla casting like that.
I work at Austin gigafactory the way they make casting is amazing there is a lot process to go from
Man that would be sweet to be around and see first hand.
Tesla - I don’t need a shirt but you make great videos! Greetings from Austria (:
Austria! Excellent, thanks. Happy new year!
Thanks for watching! Stay safe
Tesla. Thanks for the info man. My step-daughter just got hit in the front passenger wheel and looks like its bent the wheel back. Body looks ok but all the collision centers are booked up 2mo! Appreciated seeing how that cast welding went!
As long as she is alright! I have had two of these model Y so far and both had lower parts of the spindles sheared off in the accidents. Curious if hers was similar.
Love my TESLA, thanks for the video
Good job on tesla
Tesla. I was interested to see how a gigacasting weld repair might go. If Tesla is the insurer then they'll soon hone the casting vs write offs issue once the costs are tallied.
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Well, when an insurance company "writes off" a car it doesn't destroy them. It sells them. Anyone can buy it; often the owner will buy it back and make the repair at his own risk. Just like the case in a lot of accident repairs, it's likely the car might not be a "crash worthy" as before. The world isn't a perfect place.
Cars that cannot be safely repaired have to be certified as scrapped and made unusable ever again. Anything else is sold for spares or repairs.
@@davidelliott5843 -- Yet a lot of cars are repaired to less that the full standard. It's wasteful to junk perfectly good cars. I've heard that cars involved with trainwrecks are also junked.
That, again, is wasteful. Perhaps some legislative solution can be found whereby a VIN can be permanently flagged in a publically accessible federal database when certain repairs are made.
Looks like tesla will be sued out of business.
Tesla investor here. We have news almost every other big auto maker is switching to Gigacasting as its technology has been around for a decade (as Sandy Munro pointed out over and over). I guess this kind of repair will be more and more requested in the future, not only for Teslas
I would bet the majority would have a repair procedure involving adhesive bonding instead of welding. To hard to control and maintain weld variables with different people, machines, process, etc.
Great Job on the TESLA
It will be interesting to see what changes Tesla makes since they've said they plan to work on making it easier to repair their vehicles (since there is now a financial interest due to Tesla insurance).
Tesla always had a financial interest in making the cars easier to repair. They sell parts for near cost, they do not profit on parts.
@@_PatrickO Tesla do not sell parts easily. Go and look at RichRebuilds channel.
Is it still hard to get parts from them? For those of us that still DIY :)
@@froggy0162 I haven't had too much trouble except for the fact I need to do it through the app. The parts catalog is online and most parts are available.
@@_PatrickO How do you know that they sell parts near cost ...a lot of the Parts are made in China
Tesla. Nice repair.
Sweet welding
Yeah Tesla fan here you would imagine Tesla would be interested in longevity of their cars especially if they have had a fender bender .Thanks for the video new man here
Finally, someone with an objective eye on Tesla design and construction. Engineering is all about cost to benefit analysis, while so many TH-cam channels go after the Elon cult following with ridiculous hype about how absolutely perfect everything Elon touches comes out.
Elon has more haters than fans
TESLA
I was curious about how the casting could be repaired. A welder buddy makes an excellent living repairing aluminum outdoor furniture in a oceanside resort town where there are many hotels.
Great job welding the Tesla cast webbing, I agree with you a sacrificial piece would be better.
It's designed on purpose to not be fixable in a minor collision. There's good reasons why so many of these cars get written off and why insurance is so expensive on them. Design is bad for customers, great for Tesla sales.
@@truantray Nonsense
Tesla! … Great soundtrack to that too! I hope Tesla incorporates your findings on repairability
Tesla. Cool to watch an expert at work. A shop tour would be fun.
Coming soon!
Repair is not a priority. You repair it there is no new car sale. No new car sale no money. No money no Tesla. Full circle
Thanks for the feedback you got that right brother
@@thegrinch8970 although I do have a 2018 salvage M3 I wouldn't venture to get a crashed newer one
Nice bead on the welds. I was wondering if it would be possible to weld the GIGACasting. Thanks
NIce TESLA repair, congrats!
Loved the fix...... Tesla is king....... Thanks
Tesla, nice weld
Thanks for the compliment
Tesla. Being a welder it's cool to see some one give it a go on some not so easy stuff!
Tesla. 519 Guelph here! Interesting video. New to your channel.. but tesla fan
welcome! Guelph in the house 👍
Nice job with the video, good explanation and detail.
Thanks!
Tesla. Great info, I worry about the repair ability of these cast as well
Tesla great video sir happy new year
Thanks! Happy new year to you too
👍🏻👍🏻
Tesla. Will be interesting to see how this issue evolves. Good stuff.
Tesla. Thanks for showing us the repair.
Tesla! Interesting repair. Obviously this kind of fix should be acceptable some it does not bear any considerable load
Very interesting to see a giga cast repair. That first weld reveal made my jaw drop! Great work!! Tesla
Tesla! It's great that you in lude commentary on design, not just the actual repair.
thanks
great video TESLA
tesla. I think this might increase the number of hot rods being built. A totaled out model y would make a really nice drivetrain in "something other than a tesla". Nice that you were able to keep the car going, even if it's a salvage.
Electric hotrods are the future! Although, I'll get lots of hate for that... haha
tesla will incorporate stuff like this right here
Tesla, Nice work thanks for posting.
TESLA thank you, that was very interesting an informative. All the best. M
Tesla! I knew it could welded.
👍🏻👍🏻
TESLA I have been touting the use of FRP or the like for all or some of the chassis on EVs. Big oil will rejoice! Plastic can flex whereas the aluminum, as seen here, is so brittle.
Thanks. I was wondering how in clover some of this repair will be after an accident. Even an easy hit like the one you have.
Cheers, keep up the good work
very nice TESLA repair
Tesla. Great video! I agree Tesla probably won't redesign the casting but it looks like an opportunity for an aftermarket company to produce a stamped piece that bolts to the remaining portion of the casting to make the repair.
Thanks!, Yeah, that is exactly what i was thinking. Very much doubt they would change the casting so a nice little bracket would be slick
@@519Kustomz you would think they are at least planning a few revisions down the road with the casting. Maybe a few years down the road you revisit the design with some improvements.
Tesla is building a large custom die shop at GigaTexas just for die refurbishment and modification. Lots of very specific job openings posted for die shop positions. Pretty sure they'll optimize the die/subassembly interfaces to improve economics over time. One thing Tesla never does is stand still.
@@519Kustomz They're building their own die shop at giga Texas, I assume with the capability of doing their own dies. That would fit in with their usual practice of constant improvement. Thanks for your vid and yes, Tesla in the title draws eyes.
@@scottgaree7667 Yes, I heard about this die shop that Tesla was building. Definitely going to do some special things at that shop. One thing I know about die casting molds is that they are always breaking down and need a lot of service. Even more fun when these giga molds are the size of a mini van. People don't realize, these things are solid steel and are very heavy. Plus after they come out of a die casting machine, they will be extremely filthy. They will need special equipment to just work on these molds. I hope Elon is smart enough to pay these guys a good wage. Maybe even let them form a union. Lol
Tesla. Interesting to hear your views on the repairability of the giga-casting too.
wich ones? i doubt they have any out there. or what do you mean?
@@adrianhochmann3091 Hi Adrian, I’m sorry, I don’t understand your question or how it relates to my comment on the repairability of giga-castings.
@@gregbelcher937 my bad. i guess i missread your comment. i thought there were videos from tesla themselfs about the repairability of the gigacastings
@@adrianhochmann3091 Hi Adrian, no worries. Thanks for clearing this up.🙂
I’m at the Monty mark but here it is “Tesla”. Love the video keep it up!!
Month***
Tesla. Thanks for showing this process.
Tesla. I've only seen welding on low-pressure aluminum castings. Those are generally porous and start to collapse as soon as you heat them. How was the porosity of the gigacasting?
Porosity was very low. I was impressed how dense it was considering it is formed so quick. The high pressure seems to make all the difference.
Looks like body shops are going to need to have an experienced TIG welder available when necessary.
Tesla, nice video on repairing the gigacasting!
I fast forwarded to the end to see your conclusion. So, TESLA!!!
Tesla .. 2 door GigaTruck .. ASAP please ..
🙏🏼🙏🏼
I'd e interested on how you finished that off. Did you add another piece of aluminum to replicate the original, or make another bracket. I imagine it is made that way for side impact absorption. Nice work, btw. TESLA.
That was as far as i took it. This model Y is just for parts for other conversion projects so not going back on the road. I was just super curious how the base material would weld
As a Tesla owner I find this very interesting! Thanks a lot and greetings from Germany. Tesla
Thanks for watching!
Cool Tesla vid man