1. Welcome to Tacoma World!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all Tacoma discussion topics
    • Communicate privately with other Tacoma owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

Aluminum door sills

Discussion in '1st Gen. Tacomas (1995-2004)' started by SiberianTacos, Sep 11, 2021.

  1. Sep 11, 2021 at 6:56 PM
    #1
    SiberianTacos

    SiberianTacos [OP] Well-Known Member

    Joined:
    May 7, 2021
    Member:
    #365034
    Messages:
    364
    Gender:
    Male
    Vehicle:
    02 Tacoma Dbl Auto 4wd
    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
    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
    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)
    https://www.amazon.com/gp/product/B07YXB5SZ9/
    6) Sharp corners are grinded and sanded. But aluminum is so easy to shape.
    Metal File Set
    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.

    IMG_2354.jpg IMG_2353.jpg IMG_2352.jpg
     
  2. Sep 11, 2021 at 7:05 PM
    #2
    Shortman5

    Shortman5 Well-Known Member

    Joined:
    Mar 30, 2013
    Member:
    #100952
    Messages:
    2,560
    Gender:
    Male
    ..
    Vehicle:
    Supercharged TRD
    TRD S/C, ADS coilovers.
    Damn. That’s cool.
     
    tacojim02 and SiberianTacos [OP] like this.
  3. Sep 11, 2021 at 7:55 PM
    #3
    Nevin

    Nevin Well-Known Member

    Joined:
    Jan 15, 2015
    Member:
    #146446
    Messages:
    644
    Gender:
    Male
    Washington
    Vehicle:
    03 Tacoma 3.4 Ext cab SR5
    OME 881 springs with 3/8 spacer. Nitros all 4 corners. Dakar rear leafs. Deckplate mod. Marlin Crawler 1200lb clutch. Redline hood struts. ECGS clam shell bearing. Philips LED headlights. Front Runner bed bars for RTT.
    Very creative. How bout some more pics of those leather seats.
     
    SiberianTacos [OP] likes this.
  4. Sep 11, 2021 at 7:59 PM
    #4
    SiberianTacos

    SiberianTacos [OP] Well-Known Member

    Joined:
    May 7, 2021
    Member:
    #365034
    Messages:
    364
    Gender:
    Male
    Vehicle:
    02 Tacoma Dbl Auto 4wd
    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

     
    Key-Rei and Nevin like this.
  5. Sep 11, 2021 at 8:12 PM
    #5
    Nevin

    Nevin Well-Known Member

    Joined:
    Jan 15, 2015
    Member:
    #146446
    Messages:
    644
    Gender:
    Male
    Washington
    Vehicle:
    03 Tacoma 3.4 Ext cab SR5
    OME 881 springs with 3/8 spacer. Nitros all 4 corners. Dakar rear leafs. Deckplate mod. Marlin Crawler 1200lb clutch. Redline hood struts. ECGS clam shell bearing. Philips LED headlights. Front Runner bed bars for RTT.
    Ah yes, should of checked there first. Digging those sport seats. Great photos BTW. :thumbsup:
     
    SiberianTacos [OP] likes this.
  6. Sep 11, 2021 at 8:16 PM
    #6
    Slick Taco

    Slick Taco Every Day Is Taco Tuesday

    Joined:
    Aug 16, 2018
    Member:
    #263031
    Messages:
    1,447
    Gender:
    Male
    Oregon
    Vehicle:
    2019 Rav4 Lunar Rock. 2018 TRD OR DCSB KD Max tuned. 2010 Tundra 4x4 Crew Max Limited(daily driver). 1991 Ivan Stewart 4Runner Crawler Edition
    King 2.5 coil overs T.C. UCA's, Deaver leafs, 17x9 Black Rhyno Warlords, 33" Toyo M/T's, Metal Tech rear bumper, Westin HDX drop steps with Bullet Liner coating, K&N CAI Baja Designs fog pod inserts, Rigid Midnight addition 3" pod ditch lights. Cali Raised brackets and 32" behind the grill mounted light bar, Southern Style Offroad Lopro front bumper, Warn winch, FACTOR 55 Ultra Hook, FACTOR 55 Hawes Fairleed, Cosmetic goodies such as 15% carbon tint, matte black in channel rain guards, interior LED's, Teton Workshop shift knob, Inferno vinyl detailing on the interior, Cali Raised multi rocker switch cubby insert with Mc Tuning LED switches and a few other mods I've probably left out.
    Hell Yezzzzz!
     
    SiberianTacos [OP] likes this.
  7. Sep 11, 2021 at 8:19 PM
    #7
    Slick Taco

    Slick Taco Every Day Is Taco Tuesday

    Joined:
    Aug 16, 2018
    Member:
    #263031
    Messages:
    1,447
    Gender:
    Male
    Oregon
    Vehicle:
    2019 Rav4 Lunar Rock. 2018 TRD OR DCSB KD Max tuned. 2010 Tundra 4x4 Crew Max Limited(daily driver). 1991 Ivan Stewart 4Runner Crawler Edition
    King 2.5 coil overs T.C. UCA's, Deaver leafs, 17x9 Black Rhyno Warlords, 33" Toyo M/T's, Metal Tech rear bumper, Westin HDX drop steps with Bullet Liner coating, K&N CAI Baja Designs fog pod inserts, Rigid Midnight addition 3" pod ditch lights. Cali Raised brackets and 32" behind the grill mounted light bar, Southern Style Offroad Lopro front bumper, Warn winch, FACTOR 55 Ultra Hook, FACTOR 55 Hawes Fairleed, Cosmetic goodies such as 15% carbon tint, matte black in channel rain guards, interior LED's, Teton Workshop shift knob, Inferno vinyl detailing on the interior, Cali Raised multi rocker switch cubby insert with Mc Tuning LED switches and a few other mods I've probably left out.
    The ammo can center console/arm rest is classic :thumbsup:
     
    SiberianTacos [OP] likes this.
  8. Sep 11, 2021 at 8:37 PM
    #8
    SiberianTacos

    SiberianTacos [OP] Well-Known Member

    Joined:
    May 7, 2021
    Member:
    #365034
    Messages:
    364
    Gender:
    Male
    Vehicle:
    02 Tacoma Dbl Auto 4wd
    I was lucky to find a very clean one. Also it is very comfortable with leather wrap I did and the lift springs added.
     
    Slick Taco likes this.
  9. Sep 11, 2021 at 8:43 PM
    #9
    Slick Taco

    Slick Taco Every Day Is Taco Tuesday

    Joined:
    Aug 16, 2018
    Member:
    #263031
    Messages:
    1,447
    Gender:
    Male
    Oregon
    Vehicle:
    2019 Rav4 Lunar Rock. 2018 TRD OR DCSB KD Max tuned. 2010 Tundra 4x4 Crew Max Limited(daily driver). 1991 Ivan Stewart 4Runner Crawler Edition
    King 2.5 coil overs T.C. UCA's, Deaver leafs, 17x9 Black Rhyno Warlords, 33" Toyo M/T's, Metal Tech rear bumper, Westin HDX drop steps with Bullet Liner coating, K&N CAI Baja Designs fog pod inserts, Rigid Midnight addition 3" pod ditch lights. Cali Raised brackets and 32" behind the grill mounted light bar, Southern Style Offroad Lopro front bumper, Warn winch, FACTOR 55 Ultra Hook, FACTOR 55 Hawes Fairleed, Cosmetic goodies such as 15% carbon tint, matte black in channel rain guards, interior LED's, Teton Workshop shift knob, Inferno vinyl detailing on the interior, Cali Raised multi rocker switch cubby insert with Mc Tuning LED switches and a few other mods I've probably left out.
    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
     
    SiberianTacos [OP] likes this.
  10. Sep 12, 2021 at 1:49 AM
    #10
    Rockey

    Rockey Well-Known Member

    Joined:
    Jul 17, 2014
    Member:
    #134115
    Messages:
    97
    Gender:
    Male
    Hawaii
    Vehicle:
    04 Manual TRD V6 S/C 4x4
    i need to throw in some black carpet, makes it look so much cleaner
     
  11. Sep 12, 2021 at 4:09 AM
    #11
    Bivouac

    Bivouac Well-Known Member

    Joined:
    Sep 5, 2021
    Member:
    #376253
    Messages:
    1,506
    Northern Lehigh Valley Pa
    Vehicle:
    2000 Tacoma 5 speed 3.4
    Remains to be seen I bought the tires and wheels the rest came along
    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!
     
    SiberianTacos [OP] likes this.
  12. Sep 12, 2021 at 5:56 AM
    #12
    SiberianTacos

    SiberianTacos [OP] Well-Known Member

    Joined:
    May 7, 2021
    Member:
    #365034
    Messages:
    364
    Gender:
    Male
    Vehicle:
    02 Tacoma Dbl Auto 4wd
    Perhaps Stainless ? I am actually thinking of trying a steel version. But will see how these hold up.
     
    Bivouac likes this.
  13. Sep 12, 2021 at 7:00 AM
    #13
    Rhodes

    Rhodes Well-Known Member

    Joined:
    Jan 16, 2021
    Member:
    #353000
    Messages:
    104
    Gender:
    Male
    Edmonton
    Vehicle:
    01 Dbl Cab TRD
    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.
     
    SiberianTacos [OP] likes this.
  14. Sep 12, 2021 at 8:01 AM
    #14
    Andy01DblCabTacoma

    Andy01DblCabTacoma Well-Known Member

    Joined:
    Mar 12, 2021
    Member:
    #359086
    Messages:
    495
    Gender:
    Male
    First Name:
    Andy
    Vehicle:
    2001 TRD Double Cab
    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.
     
    SiberianTacos [OP] likes this.
  15. Sep 12, 2021 at 8:51 AM
    #15
    nagorb

    nagorb Should be a dang perma mod

    Joined:
    Feb 28, 2011
    Member:
    #52025
    Messages:
    9,040
    Gender:
    Male
    Alabama
    Vehicle:
    2001 dbl cab 4x4
    Nice job OP.
     
    SiberianTacos [OP] likes this.
  16. Sep 12, 2021 at 4:57 PM
    #16
    SiberianTacos

    SiberianTacos [OP] Well-Known Member

    Joined:
    May 7, 2021
    Member:
    #365034
    Messages:
    364
    Gender:
    Male
    Vehicle:
    02 Tacoma Dbl Auto 4wd
    Thank you! More of interior will be covered by aluminum
     
    nagorb likes this.
  17. Sep 12, 2021 at 9:24 PM
    #17
    treyus30

    treyus30 DIY guru

    Joined:
    Jun 24, 2015
    Member:
    #158054
    Messages:
    2,013
    Gender:
    Male
    First Name:
    Trey
    Mesa / AJ, AZ
    Vehicle:
    '99 5VZ Pre-Runner
    Twin Turbro'd; Navy blue Raptor-lined; Mid-Travel; 35s
    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.
     
    SiberianTacos [OP] likes this.
To Top