DIY Side Sills - LotusTalk - The Lotus Cars Community
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post #1 of 71 (permalink) Old 08-04-2013, 10:04 AM Thread Starter
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DIY Side Sills

I don't really care for most of the side sills that are available. Most are too large for my taste; looking more like running boards.

So, I decided to make my own...

I made a cardboard template following the body line of the car, made a CAD drawing from it, and had them laser cut out of .100" aluminum. Cost $100 to have them cut, including material. Not too bad.

I painted them with Plasti-Dip and installed them with Rivet Nuts.

I attached the .dxf file if anyone else likes them and would like to make their own. They fit my 2010 Exige S240 like a glove. No guarantee they will fit your car, but would certainly give you a good starting point.
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Jetblast and bucher like this.
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post #2 of 71 (permalink) Old 08-04-2013, 10:10 AM
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They look very similar to my Reverie carbon fiber side skirts.

I agree that some of the side skirts are very large. I've accidentally touched my foot to my side skirt exiting the car. I'd have to make a very deliberate exit if I had the APR or other large side skirts.

Nice of you to post up the specs for others.

San
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post #3 of 71 (permalink) Old 08-04-2013, 12:42 PM
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Nice job! What do they weigh?

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post #4 of 71 (permalink) Old 08-04-2013, 04:12 PM
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I really would like to do this.
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post #5 of 71 (permalink) Old 08-04-2013, 06:04 PM
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Great idea and execution! I wish someone would make a similar CAD plan for the Elise. That way we could purchase the plan and take it to a local shop to be cut.

What thickness of aluminum did you use?

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post #6 of 71 (permalink) Old 08-04-2013, 06:13 PM
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Quote:
Originally Posted by GR82DRV View Post
Great idea and execution! I wish someone would make a similar CAD plan for the Elise. That way we could purchase the plan and take it to a local shop to be cut.

What thickness of aluminum did you use?
.100" in the first post.

San
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post #7 of 71 (permalink) Old 08-05-2013, 07:50 PM
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Very nice looking pieces. I hadn't thought of making a set for my car, but now I think I will! Which rivnuts did you use?

If we are going to run out of fuel, might as well have fun doing it! ~My Father
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post #8 of 71 (permalink) Old 08-06-2013, 03:45 AM Thread Starter
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What do they weigh?
A few pounds I'd guess. I can pull up the CAD model later and measure.


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Which rivnuts did you use?
I used M6 rivet nuts with the basic installation tool from McMaster-Carr.
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post #9 of 71 (permalink) Old 08-06-2013, 04:17 AM
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Thanks!!!
When I pick up my Exige this week this and a difflow diffuser are first on the list. Do you have a close up of the edge of the sill? I would like to see how thick .100" looks. Do you think a rubber edge trim may finish off the edge nicer?

Thanks again.
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post #10 of 71 (permalink) Old 08-07-2013, 08:21 AM Thread Starter
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I rounded the outside edge with a sander before painting. I also did take a 3/16" ID fuel line that I had lying around, split it and stuck it on the edge to see how it looked. That looked fine as well.
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post #11 of 71 (permalink) Old 08-07-2013, 09:35 AM
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For those of you looking to do something similar to this and want edge trim I have found this to work quite nicely.

Good work OP they are subtle, but look very nice.

Rubber Edge Trim 1 4" Opening | eBay

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post #12 of 71 (permalink) Old 08-15-2013, 10:19 AM
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Did you have to drill holes to mount these or did you mount them to existing holes.
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post #13 of 71 (permalink) Old 08-15-2013, 11:45 AM Thread Starter
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Did you have to drill holes to mount these or did you mount them to existing holes.
Drilled new holes.

I used a depth stop gauge on my drill bit to ensure I only drilled through the fiberglass and no deeper to avoid hitting oil lines or anything else.

Last edited by da40flyer; 08-16-2013 at 12:32 PM.
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post #14 of 71 (permalink) Old 08-16-2013, 11:11 AM
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Looks nice... great work.
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post #15 of 71 (permalink) Old 08-16-2013, 12:31 PM Thread Starter
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I just installed some edge trim I found at Reid Supply. I think it finished it off nicely.

Item No: ELH-1135 [Gripping-Base PVC Door Edge Protection]

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post #16 of 71 (permalink) Old 08-16-2013, 02:09 PM
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They look great. I so need to do this!
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post #17 of 71 (permalink) Old 08-18-2013, 07:39 PM
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Stupid question... Where do I take that .dxf file to have those made?? Should I just google metal fabrication shop? Or does it need to be a auto specific place?
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post #18 of 71 (permalink) Old 08-18-2013, 10:52 PM
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Very nice. Thank you for contributing to the community with the download.

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post #19 of 71 (permalink) Old 08-19-2013, 04:35 AM Thread Starter
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Stupid question... Where do I take that .dxf file to have those made?? Should I just google metal fabrication shop? Or does it need to be a auto specific place?
Any shop that has a waterjet or laser cutter will be able to read a .dxf file. I used these guys:

Discount Steel
Jason Merrell
Texas Inside Sales
(682) 730-3008

They were actually cheaper than any of my local shops (even with shipping cost).
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post #20 of 71 (permalink) Old 08-19-2013, 06:21 AM
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Thank you for sharing!
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