Aluminum Door Sills

Materials:
5/16″ or 3/8″ Stainless Steel Screws
2″ x 1/8″ Thick Aluminum Bar

Tools:
Metal File
Jig Saw or Hack Saw
Sander or Sand Paper
Rubbing Compound or Steel Wool
Quick Clamps
Socket Set
Drill and Drill Bits
Countersinking Bit


These are the little screws that I bought for my head unit. I haven’t tested them to see if I chose the right ones yet. I have over a hundred of them, so I chose to use them for tis project. As you can see, size 8, thread size 32, flat head, phillips screw.


The first thing you should do is take off the stock plastic door sills. We will be working with them outside of the car. That is unless you want to risk drilling into the metal? To be able to take them off (at least in the coupe) we have to take off the lower seatbelt attachment bar. Simply unbolt it using the proper socket.


Let’s start on the passenger side. First take off the small piece that is closer to the front of the car. Here is what it looks like underneath. It’s only held in place with two white clips. You could be able to figure out how to take it off by looking at this picture.


Next is the long piece. See all the clips? You’ll have to be careful not to damage them. Don’t pry with too much force. Remember where each clip is and try to get them all to pop out before you take the whole piece off. The end near the plastic panel in the back will be tricky to get out and even trickier to get back in.


This is what it looks like under the small piece.


This is what it looks like under the large piece.


Now for the drivers side. First take off the cover for the lock. Then take out that golden screw.


Now, what I did was push up this lock mechanism to disengage it from the lower portion. Otherwise I think that it would get in the way when trying to remove this plastic door sill on the drivers side.


This is what the small driver’s side piece looks like.


This is what the large driver’s side piece looks like.


Now that you’ve got that stock door sill out of the car you can use it as a template for the aluminum door sill. Simply cut the aluminum bar to the right length. Then round the corners so that they match the rounded corners of the stock door sill. Use a file to do this and compare it to the stock door sill by placing the aluminum bar on top of it.


After that’s done take two clamps and clamp the aluminum bar to the stock door sill. Take care not to clamp down on one of the little white snaps on the underside of that plastic piece. I used paper towels here so that I would not scratch up the aluminum. I was also comparing it here in this picture to see what it would look like.

Now take a drill with that countersinking bit and drill holes through the aluminum and the plastic. My countersinking bit already had a regular drill bit on top of it. I used a somewhat broken up pattern so that the eyes would be fooled and not see any imperfections in the hole placement. Just be sure not to drill down too far. One mistake could cost you the project.

After the drilling has bean done you’re ready to sand the piece down. Sand the rough edges, sand the countersunk edges, sand everything. Start at a lower grit, then move up to a higher grit. I finally used rubbing compound to polish the piece. I ended up with a nice satin sheen. I had to wash the piece down to remove the dirty rubbing compound. You could wet sand as well.

Then simply screw the piece down with those stainless steel screws and you’re ready to go. Just reinstall everything first. I guess it might be easier to reinstall everything first and then screw down those pieces. Although if you buy the longer screws you can use washers and nuts on the underside to further secure the piece. I will make this switch later.

Grey from civicforums

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