Alias23: Lotus Exige S3 V6 Extended Side Sill Installation Guidelines
As an aftermarket motorsport part designed for track usage - Painting, installation, and usage is at owners risk.
These instructions are simply guidelines. A professional installation should always be sought with installation of this product. WARNING, MOTORSPORT OR DRIVING CAN BE DANGEROUS RESULTING IN DEATH OR PERSONAL INJURY. READ OUR FITTING INSTRUCTIONS CAREFULLY
This article is sold without warranty expressed or implied. No warranty or representation is made as to this product’s ability to protect the user from injury or death. The user assumes that risk. The effectiveness, warranty and longevity of this equipment are directly related to the manner in which it is INSTALLED, USED, and/or MAINTAINED. THE USER ASSUMES THE RISK.
Working on your car can be a dangerous activity. If you are unsure of what you are doing, please leave mechanical or safety critical work to a skilled mechanic. We take no responsibility for the incorrect use and / or installation of this product.
Key Tools Needed
10mm Spanner or Socket Set
Drill and drill bit set 3-9mm
Nutsert or Rivsert insert gun to fit alloy inserts into OEM side sills
Double sided tape
Step One – Get the Car in the Air
Handbrake on and follow the Lotus handbook instructions on jacking the car into the air and the placement of the four axle stands to have the car elevated to work on. Be aware Lotus weight is biased to the rear. Follow the Lotus handbook instructions!
Step Two – Clean Up
With the car in the air ensure the side sills in particular the underneath of the sill are clean (Figure 1). We will be using double sided tape in later steps and need to ensure a clean surface for bonding.
Step Three – Positioning
With the car clean, time to position the extended side sills for trial fitting and marking for drilling in step four. We found the best way to do this was to apply three pieces of double sided tape (front, middle, rear) to the extended sill so that you can press them into place, trial fit, and mark up before any final drilling.
The design of the extended sill gives you a lot of room to extend out from the side of the car as you wish depending on how much of an aggressive look you are trying to achieve. However we found around 55mm from the body at the front (to align to the front mud flap - Figure 2), and 40 mm at the rear (Figure 3) is a nice balance.
Once you’re happy with the final fit (Figure 4) and with the extended sill temporarily stuck into place with the double sided tape, mark up the drill holes underneath with a marker for step four.
Step Four – Drilling & Inserts
Once you are happy with the final appearance (Figure 4) and have marked up the holes underneath for drilling (in step three).
Remove the extended side sill from its temporary double sided tape fixing. With the extended sill removed.
You should now have six markings underneath (figure 5) and these are where the provided riv nuts will need installing for final fixing of the extended sill.
Begin to drill through the OEM GRP side sill, be super careful, and super slow, as oil pipes reside inside the actual OEM side sill! If you can, use a drill guard, to prevent any slippage and limit the drill depth into the sill!!!
Start with a small drill bit before enlarging the hole to fit the supplied riv nuts. Again be super careful and take your time!
When ready begin to install the riv nuts using your preferred nut riveter tool. We use the Sealey short arm tool which we’ve found useful given the small area working on when underneath the car.
Again take your time and be careful as you install the riv nuts (Figure 7) to ensure you don’t over tighten and crack the fiberglass.
Step Five – Final Fixing
With all riv nuts installed (Figure 7 & 8) . You’re now good to bolt on your extended side sills with the supplied washers and bolts (Figure 9). Finished!
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