I have the unique experience of being able to see the line where the battery packs are made. The pack halves are all pressure tested to ensure they won't have any leaks when assembled. There was some concern about the sealing area between the two parts of the pack where laser welded panels overlap potentially leading to leaks down the line if the sealer wasn't done just right. Normally with sealing surfaces, you want a continuous piece of metal to seal against but these packs are so big they couldn't do it this way.As some one with zero manufacturing experience, how does an issue like this occur? I know this vehicle was ambitious (both timeline and capabilities), but I also am led to believe they test everything, over-engineer and quality control the quality control. Does this happen because a late-in-the game change is made and people assume it's just as good as the original design? Or they knew the original design had risks but they thought they solved the issues based on earlier testing?
I know we are all purely speculating, but I'm still waiting for mine, so speculation is all I have.
I have no idea if they can acceptably fix it if that's what the issue is.So, as a fix, are we talking having to drop the pack and hand sealing at dealerships with the halves in situ or is this a "return the pack to the factory and have them reseal and press?"
From a legal perspective it seems like they'd just ship out new packs to dealers, ship the defective packs back to the factory for refurb.
Plug the wagon with caulk
Wonder if you'd get a "fix" quicker if you drove through 25" deep water.
1% was the number stated for the Bolt battery defects as well. I think it's just the lowest percentage they can state and they can't prove how many really are affected without inspection.I was looking for more details or any updates this morning and I reread the main report to NHTSA. This stands out at the beginning of the report:
Population : Number of potentially involved : 824
Estimated percentage with defect : 1 %
8.24 vehicles are defective and we are in this situation?