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Getting to bare metal would require so much of the vehicles interior to be removed, the chances of doing it without damaging said interior would be next to none, then doing the spot welds depending how close they are to the exterior could affect the paint, which would in turn require repainting, which would in turn require stripping the whole vehicle back to get the whole paint job even [edit: to get a perfect finish on a portion of a repair indistinguishable from the rest of a car is pretty hard]

To to go from "as new" to "Bare metal" to back again would be a logistical nightmare. There'd be so many little things "oops, damaged that plastic piece with a screw driver...binned !". And even if you did manage to get the welds in, you'd probably have to re-schedule a whole bunch of new parts for production, just for that batch.

The cost to pull that off would outweigh a new car - as it would all be skilled automotive labour (remembering you couldn't reverse the robotics that assembled part of the car in the first place).

People would be expecting to buy new cars that would have to be perfect. Even if by some miracle you did pull off getting the cars back to perfect condition, imagine if (when) the new owners found out?

291 would represent x%age of cars for that model year. Just bin them.




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