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At Munro & Associates, our passion for expert teardown analysis drives us to dig deep into every new vehicle iteration. When the 2021 Tesla Model 3 arrived at our shop, excitement ran high. We hoped to see how much Tesla had refined its engineering, particularly around long-standing concerns like paint quality, build consistency, and cost-saving innovations. In this first impressions walkthrough, we dive into what has improved — and where work remains — using our direct teardown inspection techniques. Our initial Tesla Model 3 impressions reveal both promising upgrades and persistent quality control issues.
Paint and Surface Quality: A Major Step Forward
The most immediate improvement was striking: the 2021 Tesla Model 3 exhibits a dramatically superior paint finish compared to earlier versions. Using our surface inspection tools, we confirmed that the paint showed none of the rub-through, orange peel, or inconsistency that plagued previous builds. Without even a protective wax layer applied, the finish appeared smooth, durable, and professionally executed.
For Tesla, historically challenged by painting throughput and environmental constraints at Fremont, this leap forward represents a major win. If Tesla can maintain this paint quality across all production batches, they could finally lay to rest one of the longest-standing critiques in automotive circles.
Chrome Delete and Design Refinements
Another highly noticeable design change: Tesla eliminated the chrome trim around the windows and door handles. In its place, matte black finishes provide a more modern, aggressive aesthetic — one that aligns with customer preferences and industry trends. Tesla enthusiasts have long been “dechroming” their vehicles with aftermarket kits, so this move shows Tesla’s responsiveness to market signals.
In terms of appearance and material choice, Tesla’s 2021 Model 3 continues to mature, delivering a cleaner, sleeker look that better fits the premium EV segment.
Gaps and Flushness: Improvement, But Inconsistencies Remain
Unfortunately, not all the news was positive. When we examined panel gaps, flushness, and structural alignments using our gap gauges and contour tools, inconsistencies quickly emerged — particularly on the passenger side of the vehicle.
For example:
- The front passenger door gap was too tight to fit our smallest measuring gauge, risking long-term wear or paint damage.
- Decklid alignment around the taillamps showed significant asymmetry, with large variances between the left and right sides.
- Flushness around the door panels varied enough to feel by touch, and even snagged our flushness tools.
While the driver side showed near-perfect assembly — suggesting Tesla knows how to get it right — the passenger side revealed a different story. These types of build quality issues mirror what we once saw from Hyundai and Kia in the 1990s before they made their reputational comeback.
In luxury vehicle production, especially at the price point Tesla targets, consistent gap tolerances and clean panel alignments are non-negotiable. Tesla’s progress is clear with the Model 3; but first impressions still matter, and these inconsistencies still prevent it from reaching true luxury manufacturing standards.
Door Closing Effort: Heavier Than Expected
Another surprise was the closing effort required on the doors. In previous Teslas, door closure felt light but reassuring. On this 2021 Model 3, however, the closing force was noticeably higher, almost out of character. Whether this stems from heavier seals, latch adjustments, or overcompensation to address water intrusion issues remains to be seen. We’ll dive deeper into this aspect during teardown.
Interior Fit and Finish: A New Benchmark for Tesla
Inside the cabin, Tesla’s advancements shine even brighter. From the moment we sat down, the improved ergonomics and ruggedness of materials were obvious. Notably:
- Seat support for the back and lumbar regions was excellent.
- Interior gaps and seams in the upholstery, especially French-stitched elements, appeared precise and consistent.
- Switchgear and trim panels showed better material choice and tighter tolerances.
While Tesla’s earlier interiors sometimes felt rushed or overly minimalist to the point of cheapness, the 2021 Model 3 finally competes on equal footing with established OEMs in this crucial arena.
Tesla’s new interior quality approaches what you’d expect from a BMW 3-Series or an Audi A4 — essential competitors in the luxury EV space.
Rear Seats and Passenger Comfort
A quick inspection of the back seats showed equally positive results. Stitching consistency, material robustness, and the tactile feel of surfaces all met or exceeded expectations. Entry and exit remained a bit cramped — a limitation of the Model 3’s sporty proportions — but overall passenger comfort is now in line with competitors.
Of course, no first impression of a Model 3 would be complete without noting one minor detail: the irresistible smell of a new Tesla. Light-hearted as it may be, sensory appeal plays a real role in emotional buyer satisfaction, and Tesla scores well here.
Next Steps: Full Suspension and Casting Inspection
As we prepare for a deeper teardown, our next immediate priorities are:
- Inspecting the undercarriage for build consistency and identifying any missing or compromised suspension components, particularly given recent NHTSA-related concerns.
- Verifying whether this Model 3 includes the highly anticipated single-piece rear megacasting, a major lean manufacturing innovation Tesla is pioneering.
We’ll also put the 2021 Tesla Model 3 through real-world ride and drive tests to evaluate road noise, handling characteristics, and real-world efficiency — key aspects for both engineers and investors.
Final Thoughts: Promising Progress with Room to Grow
The 2021 Tesla Model 3 shows meaningful strides in several critical areas: paint quality, interior execution, and material choices have all improved dramatically. These changes will bolster Tesla’s case as a leader in EV design and technology.
However, the persistent build variation across panel gaps and closures remains a visible Achilles’ heel — one that competitors like BMW, Mercedes-Benz, and Lucid will not forgive in the fiercely competitive premium market.
Tesla’s relentless innovation mindset, paired with a growing commitment to manufacturing excellence, will determine how far they can push beyond their early adopter base and into mainstream dominance.
Stay tuned as we lift the Model 3 onto the hoist and continue the journey into teardown territory — because at Munro & Associates, we believe that true automotive engineering understanding lies not just in how a vehicle looks, but in how it’s built.
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