Alias23 Lotus Exige V6 Side Sill Install Guide

Alias23 · Installation Guide

Lotus Exige S3 V6 Extended Side Sills

Step-by-step fitting guidelines for the Alias23 extended side sills — Lotus Exige S3 V6.

Product: Lotus Exige V6 S3 Side Sills Available HERE

Key Tools Needed

  • 10mm spanner or socket set
  • Drill & drill bit set (3–9mm)
  • Nutsert / Rivsert insert gun (for alloy inserts)
  • Double-sided tape
  • Marker pen (for marking drill holes)
  • Drill guard (strongly recommended — see Step 04)

Recommended Fitment

  • ~55mm from the body at the front (aligns to the front mud flap)
  • ~40mm at the rear
  • 6× riv nuts per side for final fixing
  • Bolts & washers supplied with the kit
⚠ Important — Please Read These are aftermarket motorsport parts designed for track usage — painting, installation and use are entirely at the owner's risk. Sold without warranty, expressed or implied. No representation is made as to this product's ability to protect the user from injury or death — the user assumes that risk. Effectiveness, warranty and longevity depend directly on how the product is installed, used and maintained. These instructions are guidelines only; professional installation should always be sought. If you are unsure, leave mechanical or safety-critical work to a skilled mechanic. Motorsport and driving can be dangerous, resulting in death or personal injury. Read these fitting instructions carefully.
Step 01

Get the car in the air

Handbrake on, and follow the Lotus handbook instructions for jacking the car and for the placement of the four axle stands to elevate the car safely for work.

Safety Be aware that Lotus weight is biased to the rear. Always follow the official Lotus handbook procedure for jacking and supporting the vehicle.
Step 02

Clean up

With the car in the air, make sure the side sills — and in particular the underneath of the sill are clean. Double-sided tape is used in later steps, so a clean surface is essential for a good bond.

Step 03

Positioning & trial fit

With the car clean, position the extended side sills for trial fitting and for marking the drill points in Step 04. We found the best method is to apply three pieces of double-sided tape (front, middle, rear) to the extended sill, so you can press it into place, trial fit, and mark up before any final drilling.

The design gives you plenty of room to extend out from the side of the car, depending on how aggressive a look you're after. We found a nice balance at around 55mm from the body at the front (aligning to the front mud flap — Figure 2) and 40mm at the rear (Figure 3).

Once you're happy with the final fit (Figure 4), with the extended sill temporarily held in place by the double-sided tape, mark up the drill holes underneath with a marker ready for Step 04.

Tip: Take your time at this stage — getting the stance and alignment right before you mark up means the drilling in the next step lands exactly where you want it.
Figure 2 — Front: ~55mm from the body, aligned to the front mud flap.
Figure 3 — Rear: ~40mm from the body.
Figure 4 — Happy with the final fit and stance before marking up.
Step 04

Drilling & inserts

Once you're happy with the final appearance (Figure 4) and have marked up the holes underneath (in Step 03), remove the extended side sill from its temporary double-sided tape fixing.

You should now have six markings underneath (Figure 5) — these are where the supplied riv nuts will be installed for final fixing of the extended sill.

⚠ Critical — oil pipes inside the sill Begin to drill through the OEM GRP side sill super carefully and super slowly — oil pipes reside inside the actual OEM side sill. If you can, use a drill guard to prevent slippage and limit drill depth into the sill. Start with a small drill bit before enlarging the hole to fit the supplied riv nuts. Take your time.

When ready, install the riv nuts using your preferred nut-riveter tool. We use the Sealey short-arm tool, which we've found handy given the small working area underneath the car.

Don't over-tighten: take care as you install the riv nuts (Figure 7) so you don't over-tighten and crack the fibreglass.
Figure 5 — Six markings underneath, ready for drilling and riv nuts.
Drilling slowly through the OEM GRP sill, small bit first.
Figure 7 — Riv nuts installed — take care not to over-tighten.
Step 05

Final fixing

With all riv nuts installed (Figures 7 & 8), you're now good to bolt on your extended side sills using the supplied washers and bolts (Figure 9).

Figure 8 — All riv nuts installed and ready.
Figure 9 — Bolt on with the supplied washers and bolts.
★ Finished That's it — your Alias23 extended side sills are fitted. Stand back, check the stance from both sides, and make sure everything is secure. Enjoy.
Alias23 · Exige S3 V6 Extended Side Sills Installation Guide · alias23.com

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