Tonneau cover leak DIY fix (cause: seal strip gap under aero flap)

[wheeler]

I noticed that most leaking in my CT bed during rain and carwash happened in one spot under the aero flap.

So I took the aero flap off, found out that the seal strip under it has a gap right at the leaking spot.

Comparing the left and right mounting locations of the aero flap, I also noticed the seal strip is very off at the left end, almost missing. (Marked green in photo.) And the roof glass is not well aligned .(Red marks.)

I filled the gap, put the aero flap back, then the leaking is gone, at least for now.

@Technigogo posted a video showing detailed instruction to take off and put on the aero flap, in case anyone needs to watch it.

 

[BChiesa]

Good to know. Thanks!

 

[Treynor]

THIS is valuable info!
thanks for helping all of us increase the quality of our CT!
good post.

 

[joeliroquai]

What did you use to fill the gaps?

 

[JBerger]

well done

 

[wheeler]

What did you use to fill the gaps?

E6000 and random elastic foam. Not sure how long they can last though.

 

[The Tesla Guy]

Maybe this is a silly question.
Why not take it to a service center?
I think it helps make the engineers aware of a problem in the field, allowing more permanent solutions in both the manufacturing and after delivery repairs.

 

[Cyber Man]

Great info! Thanks for sharing. I saw some video footage of Tesla engineers taking CT to car wash and the engineer getting inside the truck bed with Vault closed. I’m sure he was there to test the leak. No idea how they missed this gap. Hope they fix it soon.

 

[futureproof]

I guess $100K doesnt buy what it used to.

 

[kosmo886]

I noticed that most leaking in my CT bed during rain and carwash happened in one spot under the aero flap.

So I took the aero flap off, found out that the seal strip under it has a gap right at the leaking spot.

Comparing the left and right mounting locations of the aero flap, I also noticed the seal strip is very off at the left end, almost missing. (Marked green in photo.) And the roof glass is not well aligned .(Red marks.)

I filled the gap, put the aero flap back, then the leaking is gone, at least for now.

@Technigogo posted a video showing detailed instruction to take off and put on the aero flap, in case anyone needs to watch it.

I have the same issue. Why not simply silicone it to avoid needing to disassemble? My gap is right at the water drop in the photo. Was going to just put some silicone caulking over that portion of the strip. I'd think it should do the trick.

 

[EricM]

They might’ve changed the design on newer build trucks because mine doesn’t look like that at all (or they left the foam out of mine). Mine sure leaks like there’s nothing there.

 

[Sirkevin]

Is the gap at the end of the roll normal ? water get though.

 

[wheeler]

Is the gap at the end of the roll normal ? water get though.

Not normal. Mine is like this:

 

[wheeler]

They might’ve changed the design on newer build trucks because mine doesn’t look like that at all (or they left the foam out of mine). Mine sure leaks like there’s nothing there.

It looks to me that there is a dislocation of the whole seal strip towards the front of the vehicle. Same as the left end of mine(Marked with green lines).

 

[Sirkevin]

thanks i got a repair schedule for it when i picked it up because it was leaking already.