Tesla's New Gigacast Sectioning Technique Used to Repair JerryRigEverything's Cybertruck

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Following the infamous “durability test” by Zack from JerryRigEverything, where he subjected a Cybertruck to extreme vertical loads that don’t actually occur in reality, Zack has now gotten his Cybertruck repaired. 

While the original test created a stir, the real story is the follow-up from Tesla, which helps highlight Tesla’s approach to vehicle repair while also providing some insight into the work that went into engineering Cybertruck.

The whole incident has also caused Tesla to update its owner’s manual to show the maximum weight at different distances from the hitch receiver.

Tesla added more information to the Cybertruck's owner's manual in update 2025.14

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Gigacast Sectioning

The repair process was documented in a new video from JerryRigEverything (below), and was centered on a unique procedure that Tesla calls gigacast sectioning. This new method allows Tesla Service to field-replace only the damaged portions of the vehicle’s large rear casting rather than the entire component. This helps save time and cost while maintaining the same level of durability and structural strength.

Wes Morrill, Tesla’s lead engineer for the Cybertruck, commented on the process on X, framing it as an intentional outcome of the design process.

“Zack's repair was a perfect demonstration of the work the team put in hand in hand with service to consider repairability in the design. Crashes happen and lowering the cost of repair lowers the cost of insurance, and improves overall cost of ownership. Couple that with low maintenance costs and low $/mi and it's really hard to make an argument to buy anything else.”

The Cybertruck was not only designed to be durable but also easily repaired.

Tesla’s Repair Ethos

Beyond this specific repair, Wes also emphasized the collaborative nature of the repair experience and Tesla’s philosophy on service transparency.

“I'm also really happy to see the highlight on documentation and transparency of Tesla service. There is so much information both on Tesla's website as well as on the vehicle's UI to empower customers to learn about their vehicle and even repair it themselves if they want.”

This aligns with Tesla's principles, which have included opening patents to accelerate EV adoption, and now extends to trailblazing the right-to-repair movement. Alongside that, the service engineering team is also working on expanding the right-to-repair movement by building comprehensive documentation and opening up Tesla’s tools to make repairs and technology more approachable. 

This expansion has been evident in the recent opening of Tesla’s Electronic Parts Catalog, which allows customers to order parts directly, as well as in recent software updates that introduce features from the technician-focused Service Mode+ to the regular Service Mode, which is accessible to all customers.

The Original Test

Wes also commented on the original test - to educate on the engineering principles at play in Zack’s test, and to clarify a common point of confusion between tongue weight and overall tow capacity.

“Zack's test demonstrated ~10x factory of safety on rated tongue weight. This should inspire confidence to use the vehicle up to its maximum rating,” says Wes.

Tongue Weight vs Tow Weight

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Wes also pointed out that this thread from Bearded Tesla on X provides an excellent analysis of the difference between tow weights and tongue capacities.

While the spectacle of the initial “durability test” garnered widespread media attention, the subsequent repair and dialogue surrounding it reveal far more information about the Cybertruck's durability and repairability.

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Tesla Teases New 7-Seat Model Y

The third row in the first-generation Model Y

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In a move that’s sure to excite those with larger families, Tesla has started teasing the return of the seven-seat configuration for the Model Y. In a new marketing email sent out to customers recently, Tesla explicitly highlights the vehicle’s spaciousness.

“Ready for anything with long range, seating for up to seven, and enough room for everyone’s gear.”

The seven-seat Model Y was initially offered in late 2021, but it hasn’t been available since Spring 2023. The return of the new variant will be an addition that many have been waiting for, as the next vehicle with that much passenger space in the line-up is the Model X, starting at almost double the price.

First-Gen Model Y Third Row

The original seven-seat Model Y was extremely popular in the Asia-Pacific and European markets, and it still sold fairly well in North America despite differences in preferred vehicle sizing and spaciousness. It offers additional seats for larger families with young children, but space in the third row is minimal.

The seven-seat variant makes the Model Y more competitive against other three-row SUVs on the market. The video below features the seven-seater, first-generation Model Y.

Power Reclining Third Row?

The refreshed Model Y was launched with power-reclining second-row seats, a huge plus for practicality and ease of use. The power-reclining second-row seats are extremely popular with families and are very helpful, as you can control them from the front screen rather than needing to open the rear doors.

Tesla is likely to integrate power-reclining seats into the third row and potentially keep them for the second row as well. With the second row sliding forward and backward for easy entry, as well as allowing the second and third rows to fold flat for additional cargo room when needed.

Launch Date and Price

Tesla’s tease of the seven-seat variant is likely just the start. With recent sightings of the Model Y Performance variant hitting the Nürburgring, it seems Tesla has a lot in store for this summer. If you’ve been waiting for the seven-seat variant, it seems like it’ll be just a few short months away at this rate.

While we haven’t seen any production samples or other details regarding dates yet, Tesla previously priced the seven-seat option at an additional $2,000 USD ($3,000 CAD). The seven-seat option will likely only be available on the Long Range AWD and Long Range RWD variants, not the Performance model, similar to the first-generation Model Y.

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Tesla’s First Autonomous Vehicle Delivery to Happen on June 28th

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In Elon’s flurry of posts on X about FSD yesterday, he also revealed the date that another moment of peak science fiction would be occurring — June 28th. Tesla expects to conduct the first-ever self-delivery, where a brand-new Model Y will depart from the production line and arrive directly at its new owner’s home without any human intervention.

Imagine ordering a vehicle, and a few days later, rather than needing to pick it up, it simply arrives in your driveway and notifies you via an app that it has arrived. That’s no longer the talk of science fiction; it is quite literally something that is likely to happen this month.

Expect a Model Y Delivery in Austin

Considering everything Tesla has done so far, we’re fairly certain that the first self-delivered vehicle will be a Model Y in Austin, in the same geo-fenced area where Tesla’s Robotaxi will operate. FSD is highly optimized for the Model Y, and it’ll take some time for those optimizations to trickle down to the rest of the fleet. It’s not clear if FSD performs better on the Model Y because it’s the most popular vehicle and, therefore, Tesla has the most data for it or if Tesla explicitly chose to focus more on their most popular vehicle.

Tentatively, June 22.

We are being super paranoid about safety, so the date could shift.

First Tesla that drives itself from factory end of line all the way to a customer house is June 28.

— Elon Musk (@elonmusk) June 11, 2025

Why Self-Delivery?

While a car driving itself is something truly different from what other manufacturers offer, there are also numerous strategic advantages for Tesla to do so. This includes drastically reducing last-mile delivery costs by minimizing the need for car carriers, delivery drivers, and even delivery personnel at your local Tesla center. For customers, it could mean a faster, more flexible delivery method - and one absolutely unforgettable welcome to Tesla ownership.

We recently took a closer look at the advantages and disadvantages of vehicles delivering themselves to customers. While it’s all positive for Tesla, there are some potentially negative sides to it as well.

A Futuristic Glimpse

When you step back and look at it, Self-Delivery is a logical extension of Unsupervised FSD and the Robotaxi network in general. Self-deliveries are expected to run on the same software stack that powers the Model Ys currently roaming Austin’s streets autonomously, which means there is little for Tesla to do other than enable specific instructions for self-delivery during the final vehicle configuration steps.

Robotaxis currently run a newer version of FSD than what’s available to the public, but these self-delivered vehicles will likely be on the same version when they’re delivered.

Given Elon’s note that the dates could shift, this could easily be moved to early July; however, either way, it seems like we’re just weeks away from this monumental event, which will further reduce the cost of Tesla vehicles.

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