Aluminum Floors - LotusTalk - The Lotus Cars Community
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post #1 of 9 (permalink) Old 05-14-2019, 12:00 PM Thread Starter
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Aluminum Floors

Hey All,
Tried my hands on a new project this weekend. Thought I would share the progress.

Been looking for a different type of floor covering for the Exige, but didn't want to go the direction of rubber or carpet. Truth be told I'm kinda in love with the Williams Singer Porsche, but it's going to take me an entire lifetime to fill the wallet with the cash needed to have that.
So I thought I would take some elements I liked and start playing with some ideas.

I really loved the die cut and dimple died look of the interior and floors, so I bought some tools and tried to have a go. Below are the steps sop far. This will be an evolving project, and I'm going to make a bunch of different versions to test and play with. Maybe in the future I may also just make these on the side for people, who knows. Throw me your thoughts and suggestions.

First step was to make the pattern, pretty simple just made out of cardboard and then transferred to .50 Aluminum. Bought the materials local from Bayshore Metals in SF. Cut out the metal with a cheap old bandsaw with a metal blade, and then a belt sander.

Next was the layout for the Dimple Die holes. Bought the dimple dies from Eastwoods, and they have held up well. Normally this would be easier for a press, but I like the bolt/cut options that are manual because it allows me to get into tight spaces.

For the edge of the panel I bead rolled it so it allows the floor to lay flat on the main floor. When you dimple the holed it need about .25 depth below the panel. Then I drilled the holes for the mounting points and added a small amount of (dime side) dab of sound deadening at the front area to keep the panel flat and vibration free.

On to the next one....
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post #2 of 9 (permalink) Old 05-14-2019, 12:11 PM
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I love it! Twelve cup holders too.

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Last edited by David Craig; 05-14-2019 at 12:11 PM. Reason: spelling
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post #3 of 9 (permalink) Old 05-14-2019, 12:42 PM
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Love it
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post #4 of 9 (permalink) Old 05-15-2019, 03:20 PM Thread Starter
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Here ar ether floors in black anodized. Thought I would try something else to see how I like it.
Also added more dimple dies to the passenger side, going to go back to the drivers and add more also to match.

Think I will also play with some other designs, and use my bead roller to play with shapes. If anyone has some ideas let me know. I'll play with them and see how it looks.
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post #5 of 9 (permalink) Old 05-19-2019, 08:30 AM
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These look great!
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post #6 of 9 (permalink) Old 05-19-2019, 10:21 AM
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I also like how they look, esp the right side with more holes; and more holes == added lightness.

I worry a little that they may be too slippery, though the holes should help in that regard. Have you considered treating the surface to somehow give it a bit of a brushed or lightly roughened finish? Maybe an aggressive sand blast or shot peen before it's anodized?


'08 Arctic Silver Exige S240
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post #7 of 9 (permalink) Old 05-20-2019, 06:05 PM Thread Starter
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Glad you guys are liking them.

I need to keep going on them it's a good idea and concepts, just have not found the shape and hole pattern yet that I think is best. After I get the shape right and the details I will try a few different finishes. Right now the black is a little to computer case for me. Really trying to get a Singer Porsche kinda detail and finish.

Next up I'm going to play with different holes sizes and dimple die patterns. Just bought a reverse dimple die that cuts the hole, and bead flanges it like the Singer floors. Also considering a changeable pattern that screws into the main floor.

Will have some photos up in a week or so, right now I'm trying to finish some work on my 550.

Thanks All!
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post #8 of 9 (permalink) Old 05-20-2019, 06:11 PM Thread Starter
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Attached is the Singer floor, and then another I think is interesting with recessed bead rolled area.

Maybe I need to make them less flat lay in and give them a slight kick up angle??
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post #9 of 9 (permalink) Old 05-20-2019, 07:01 PM
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Novel. I like it.

Anyone can make something complicated. It takes genius to make it simple. Einstein.
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