Aluminum door sills

Really hated the plastic door sill on this truck. Wanted a little more tank look. Made my own aluminum door sills today. Needs a little more sanding where plastic meets it. But I will be adding aluminum interior pieces in the cab. We shall see what comes of it.
(Lets get this out of the way: This is not a HOW TO. Please do anything to your vehicle at your own risk and I am not responsible for anything you do to your vehicle.)
Parts used to make this happen:
1) M5-0.8 x 50mm

$10 M5-0.8 x 50mm Hex Socket Head Cap Screws, 304 Stainless Steel 18-8, Flat Countersunk Machine Screws for Furniture, Binding, Machinery, Automotive, DIY Projects, 30 PCS

https://www.amazon.com/gp/product/B08P1WBG84/
2) Twist Drill Bits 7mm High Speed Steel 4341 with 7mm Shank (you will need this for rivet nut insert size) 3) M5 Rivet Nuts 4) Hand Rivet Nut Tool Head Nuts Manual Riveter

$30 HIFESON Hand Rivet Nut Tool,Handy Rivnut Tool - Metric & SAE with 30pcs Steel Rivet Nuts，Rivet Nut Kit with Sturdy Case Packed, Designed for Tight Space

https://www.amazon.com/gp/product/B08SBM1J1C/
5) 2 1/2" Wide Flat Aluminum Threshold 1/4"
(You will need to cut it using either a saw or hand grinder. See my picture for fit below)

$30 2 1/2" Wide Flat Aluminum Threshold 1/4" High Made in USA by Randall Part Number A-70-M (3 FT Long)

https://www.amazon.com/gp/product/B07YXB5SZ9/
6) Sharp corners are grinded and sanded. But aluminum is so easy to shape.
Metal File Set

Jecarden 20PCS Metal File Set, File Set, T12 Alloy Steel File Tool, Large Flat / Half-Round / Triangle / Round File 14PCS Needle Files / 1 Brush for Woodwork, Great for Plastic, Metal Glass, Leather

https://www.amazon.com/gp/product/B091GR53TP/
I have to leave for a trip to Washington state. But when I return, more pictures will be posted of under the sill. How I drilled and added rivets.

 

Damn. That’s cool.

 

Very creative. How bout some more pics of those leather seats.

 

I had about 3 sets of seats in last 3 month. These are Caribou seats. Still not perfect for me. Search continues for the seats.
But yea checkout my media library

 

Ah yes, should of checked there first. Digging those sport seats. Great photos BTW.

 

Hell Yezzzzz!

 

The ammo can center console/arm rest is classic

 

I was lucky to find a very clean one. Also it is very comfortable with leather wrap I did and the lift springs added.

 

Well done. The cup holders are tits. Seeing your interior brings back fond memories of my 03 access cab that had the same interior. That mini strut for the ammo lid is a nice touch

 

i need to throw in some black carpet, makes it look so much cleaner

 

I know in my part of the country that aluminum would take constant attention to keep from corroding from all the winter chemicals and industrial slop I drag into my truck.

You did a nice job it looks good!

 

Perhaps Stainless ? I am actually thinking of trying a steel version. But will see how these hold up.

 

This. Is one of the raddest things I’ve seen in a while. I have been looking for a replacement sill as my drivers side is butchered bad. Thanks for this! Gonna give it a try.

 

That's awesome!

I just got a set (driver and passenger) from another member. They aren't the right color for my interior, so I'm going to use them to make some moulds for composite sills- carbon or glass.

I haven't had sills for 15 years... it's the number one thing my partner hates about my truck- drives her nuts.

 

Nice job OP.

 

Thank you! More of interior will be covered by aluminum

 

This is great man. A long time ago my screws stopped locking the plastic strip in so I had tack welded nuts under it and replaced the screws with bolts. This is a much better solution.