I’m assuming some skills similar to ICE car rebuilding and some completely different. So if I wanted to rebuild a Tesla from a junkyard what skills will I need?
There are some Youtube videos on rebuilding Teslas you might look at:
https://www.youtube.com/results?search_query=rebuild+tesla
Saw a bunch of those before posting the OP. Still doesnt break down what skills are needed.
I’ve never tried to rebuild one, but have owned a couple and lurk a lot on Tesla forums. There are a few people doing this, however Tesla doesn’t seem to make it easy.
First, for the strictly mechanical/cosmetic parts any mechanic should be able to handle the tasks. Suspension, brakes, body panels etc. are standard. (Although some/all are aluminum)
Next you will need some serious electrical knowledge. The battery pack is high voltage and can do serious harm if not handled properly.
Computer/hacker skills come after that. The vehicles are basically rolling computers. Everything must be programmed and Tesla is not keen on giving people access.
Finally, expect little to no help from Tesla. The tales from the rebuilders pretty much say Tesla disavowes the cars after a salvage title is issued. Parts are hard to get, repair manuals are finally getting published after a long fight and the computer stuff is still held very close. There is apparently a way to get the car ‘recertified’ By Tesla, but don’t expect stuff like supercharging to work or any future software updates.
Search around the Model S forums on the Tesla Motors Club website for a few detailed project reports. Spoiler: it can be done, but expect headaches and roadblocks along the way.
The ‘no future software updates’ part could make all the work/success pointless at any given moment, I should think.
Some owners insist on sticking with an older “stable” update as the new ones can be buggy. YMMV, Tesla seems to have a flexible mindset…what one employee says is impossible, another says no problem. According to the poster on the previously mentioned website (who just started rebuilding his second Model S) Tesla has become somewhat more friendly to salvage car owners. He also had a background in software engineering that really smoothed the process. Some other posters seemed to imply that strong computer skills may help in recovering the ability to supercharge or get updates. I’m not a tech guy, so I’m not sure entirely what all that may entail or the legality of that kind of stuff.
Another issue is that it is not that simple to be sure things are all Ok. The battery pack, for example, is a huge collection of somewhat oversized AA cells. Even hoisting the car improperly (i.e. not by the lift points) could damage the battery pack. The battery pack is flooded with coolant, to limit the temperature range the batteries go through and reduce deterioration. Unlike a mechanical engine, where if it is bent it simply doesn’t turn, an electrical device can be interesting if damaged. I presume this means if a car were damaged in a flood, there’s a risk of corrosion in the battery; there’s a video online of someone taking a pack apart, but I don’t think they are meant to be serviced or repaired - I can see why Tesla does not want to get into the recertify business. Easier to recycle the material and use a new battery pack. Same with high-voltage components. (Plus, as mentioned earlier, Tesla is reluctant to provide details on their product and how it works.)
I don’t think declining upgrades is an issue - if it works, it works. The problem with rebuilding may be that at a certain point, you find a common computer problem - it may be you cannot jump too many versions if you choose to upgrade and you are forever locked into the oldest version (without support). However, Tesla (Elon) has said they will be continuously upgrading components rather than having “Model Year” changes. It might be that you end up with a salvaged computer that expects a component that does not match what it was programmed for (too old, or too new). More likely it’s a matter of finding an assortment of components to restore what is essentially one device almost functional (I.e. replace the glass, front driver’s side body, wheel suspension steering and motor) rather than recreating Johnny Cash’s song “One Piece at a Time” with a Tesla.