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Old 04-27-2009, 06:13 PM   #1
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How To: Custom Door Sill Plate

This wasn't my idea, but I thought I'd get around to doing it, along with a how to. This idea came from bluefront:

Originally Posted by bluefront View Post
And a custom sill plate from Home Depot made out of a rubber stair tread $2 per door.

This is an inexpensive mod that you can easily do. This is my first "official" how to so bear with me and I hope everyone can follow it. (there'll be a test later. )

Tools needed:
Three rubber stair treads (two if not a sedan)
Double sided carpet tape
A pair of utility shears
A box cutter or razor blade
A heat gun
2 Different colors of spray paint (optional)
Clear coat (again, optional)
Glass cleaner and paper towels
2" sticker lettering (optional)
Tape measure

Okay, the painting and lettering are optional. You can still do this mod without them. I just wanted a more eye-catching look with mine. Here we go.

Start by purchasing the items needed. I got the stair treads and carpet tape at Home Depot and the black paint, clear coat and 2" lettering at Walmart. These are what the stair treads will look like when you go to buy them:

Measure the door sill of your Focus. You can actually get the sill plate to go under the door seal.

Once you get the measurement, use the utility shears to trim the stair tread to fit.

I also trimmed a bit from the lip for a better fit.

Once you get it trimmed, use the heat gun to soften the plastic up check the fitment. The heat gun will make the plastic easier to work with. Make any additional trims as needed to get the fitment correct.

Now comes the decorative part. Start by using some window cleaner and clean the piece.

Then, use one of the two colors of spray paint to paint the piece (I used matched paint). This layer of paint will be the color of the lettering once we are done (any Military peeps that's ever painted bumper numbers on vehicles will know this technique).

Once the paint is dry, determine what you want your door sill to say. Use the 2" lettering and apply it to the piece.
NOTE: I recommend using the tape measure to find the middle and start applying the lettering there. The tape measure will also allow for even spacing between letters. Continue until you get all the letters applied.

Once the letters are applied, take the other color of paint (I used Gloss Black), and paint over the piece again, letters and all.

Once the paint is dry (recommend letting it dry overnight), use a box cutter or other razor blade and VERY CAREFULLY peel the lettering off. The razor is more for just starting the peeling process. Once you get the letter started peeling, you can use your hands to remove it. Continue until all the lettering is removed.

Apply clear coat.

Reclean the back side of the piece, if needed, then apply the double sided carpet tape.

STEP 10:
Clean the door sill. Use the heat gun again to soften up the plastic for the final fitment.

Once the final fitment is complete, then peel off the other non-sticky part of the tape, apply and TA-DA!!!

For some added uniqueness, this is how I did the back sill plates:

The clearance between the door and the sill plates are fine and the lip will contact with the rubber door seal at the bottom of the door.

If you do not want to do the paint and lettering, you can still follow these steps to apply just the plain, black piece. I hope you were all able to follow this. If you have any questions, let me know. Enjoy.

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Last edited by CJohn364; 05-02-2009 at 10:21 PM.
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