Musk scolds Cybertruck designers for poor quality, wants panel gaps with "Lego-like" machining

Cal Jeffrey

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Bottom line: Tesla's Cybertruck is supposed to start production by year's end. However, it might get another delay, as Musk criticized the latest production demo model for its panel gapping. Ideally, he wants those panels to fit together like "Legos."

I know it's only been about four years, but it feels like decades have passed since Elon Musk promised to bring his Cybertruck to market. It is getting closer, but the latest production candidate left Musk less than impressed. He chastised employees regarding its lack of precision, saying that even Legos and soda cans are machined better than the truck's panels.

"All parts for this vehicle, whether internal or from suppliers, need to be designed and built to sub 10 micron accuracy," Musk said to employees in an internal email obtained by the Cybertruck Owners Club. "That means all part dimensions need to be to the third decimal place in millimeters and tolerances need to be specified in single digit microns. If Lego and soda cans, which are very low cost, can do this, so can we."

The email comes after Musk tweeted images of himself driving the latest version of the long-awaited vehicle. Even without zooming, the inconsistencies in panel gaps are glaringly obvious. For instance, note the areas near the headlight and driver-side windshield in the tweet below.

Bob Lutz said inconsistent panel gaps are a big deal, and he should know. Lutz has spent most of his professional life in the automotive industry, including running the top three US car manufacturers, Ford, Chrysler, and General Motors. He was also partially responsible for ushering in the BMW 3 series back in the day.

"Customers may not visit showrooms with gap gauges, but they do unconsciously register the harmony and 'one-ness' of a car with gaps so narrow that it looks like a seamless shape," Lutz wrote in an op-ed for Road & Track. "It's a visual manifestation of precision, care, and thus, quality."

Indeed. While a car does not need to be utterly seamless, there does have to be a consistency between panels that is both uniform and narrow enough to give the appearance it's well-built. Customers will subconsciously notice tiny flaws like this and pass on the purchase without even knowing why.

It is even more crucial for the Cybertruck thanks to its janky unveiling and the many setbacks and delays it has faced. You may recall Musk bragging about the truck's "unbreakable" Tesla Armor Glass during the vehicle's 2019 unveiling, only to have his design lead come on stage and embarrassingly shatter two windows. Musk later blamed himself for weakening the glass base with a few sledgehammer strikes to the door.

If Cybertruck engineers are to meet Mr. Musk's precision standards, they had better get busy. The truck is scheduled to start mass production by the end of the year.

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I'm curious about the beam pattern you get at night from those teeny weeny headlights.

I have a Model 3. The headlights look pretty big... but the part of them that is actually the headlight (and not DRLs, blinkers, etc) is tiny. The coverage is excellent. The same is true of my 2009 Mini. Only a small part of the large headlight is the actual headlight.
 
" "That means all part dimensions need to be to the third decimal place in millimeters and tolerances need to be specified in single digit microns. If Lego and soda cans, which are very low cost, can do this, so can we.""

This just shows how little this guy knows about building cars and the differences between a single piece lego design and the tens of thousands of parts that goes into building a car. F1 might have tolerances in their cars Elon wants, but those cars cost over $100 Million. It's not necessary to get every component on a truck to have "single digit micron..." tolerances and it would be prohibitively expensive to do so.
 
This just shows how little this guy knows about building cars and the differences between a single piece lego design and the tens of thousands of parts that goes into building a car.
No, this just goes to show that Musk is a nit picking, micro managing a**hole, comprehensively consumed with his own self imagined greatness, that likes to hear himself talk, preferably on camera..

My vote for the final color is still, "Fecal Brown Metallic".
 
Ok, so, panels are allowed a deviation of 0,001mm.
Forget it. It's a car, not a soda can.
Even 1mm deviation would not really be visible, I'd think.
But 0,001mm?
What planet are you from?
Oh, wait, Mars...
 
Yeah, good luck, too bad there's no supplier on Earth that can do this kind of precision. There's not even measurement tools for things this big to measure with such extreme precision to begin with.

Has it ever occurred to the master genius Musk that a Lego block or a Pepsi bottle cap is several orders of magnitude smaller than a Gigacast truck body?
 
So, a cartoonish look + bad quality + super expensive is surprising Lemon Musk that's not selling well?

How long it took the genius to realize this??
 
The GarbageTruck will be delayed again...!

Hey, it is stainless steel... It doesn't rust...!
 
"That means all part dimensions need to be to the third decimal place in millimeters and tolerances need to be specified in single digit microns. If Lego and soda cans, which are very low cost, can do this, so can we."
Good luck with that! Do they even have measuring devices calibrated for under 10 microns? Not even Mercedes in their glory days managed such tolerances for mass-produced vehicles.
 
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