DIY Network

Aluminum Floor-Mats: Installation From "Tricked Out" episode DTRK-111

Our project car, a 2001 Mitsubishi Eclipse Spyder GS, gets some impressive modifications to give its interior some sparkle.

In this episode of Tricked Out, host Andrew Totolos performs a few interior mods on a 2001 Mitsubishi Eclipse Spyder GS. He creates a set of custom cut diamond-plate aluminum floor mats and highlights them with glowing EL wire. To tie it all together, he makes a matching diamond-plate foot rest and installs aluminum pedal covers. In this segment, with the template patterns transferred onto the aluminum, Andrew cuts out the new mats using a jig saw. After the mats are cut, Andrew files the edges and bends the mats to shape them to a proper fit in the car.

Materials used in this episode:

Standard automotive tools
4-by-4 sheet of aluminum (preferably 16-gauge)
Pedal-cover kit
Existing floor mats from car
Cordless drill
Jig saw; metal blades
Hammer
Flat file
Center punch
Drop cloth
Masking tape
Permanent marker
Hook-and-loop tape
Lint-free cotton rags
Rubbing alcohol
Scissors
Clear plastic tubing
Adhesive
Extra wire
Electrical tape
Wire crimpers
Wire connectors
Silver paint marker
Safety glasses; protective gloves

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Figure A

Cutting the Aluminum Mats

• Before you make the first cut into the sheeting, you'll need to make sure that the aluminum is really secure. Either clamp it down in several locations to a sturdy table (figure A) or have one of your brute friends hold it down tightly.

  Safety alert! Be sure to wear goggles and gloves while working with the sharp aluminum.
  

  
  

• To cut the aluminum, use a jig saw with a fine-tooth metal blade. Carefully cut around the inside of the traced lines (figures B and C).

• Cutting Tip: Take your time. Let the blade do the work with minimum forward pressure on the cut.

• The blades wear out fairly quickly, so plan on using about one blade per mat. When the blade doesn't slide easily through the metal it's time to change it out. Don't skimp on this part. The blades are pretty cheap, and sharp blades mean less finishing time.

  Figure B

  Figure C

  
  

  
  

• If it's your first time cutting sheet metal, cut one of the rear floor mats first so you can get some practice on the easier ones (figure D).

  The passenger side is a little more challenging. If the corner is too tight for the blade, back up and repeat the cut at sharper angles until the curve is correct (figure E).

  Figure D

  Figure E

  
  

  	Figure F
  	Figure G

  
  

• Knock off the sharp edges of the metal with a file to complete the cuts.

• Now that the mats are cut, use the marks that were made earlier as a guide to bending them into the right shape. Use the edge of a table or workbench to provide leverage. Try to make sure that the bends "roll" rather than crease (figure F).

• Once you've bent the mat, place it in the car to check for fitting (figure G). Chances are the first time you put the mat in the car it won't fit. Just take it out and bend it some more.

• The rear floor mats are usually flat and should just drop into place. Make sure there is a tight fit with all of the mats and then take them back to the bench to fit the lights.

• The footrest is relatively easy to install. Just screw the factory footrest back into place. Wipe it clean, and then attach the new footrest using industrial strength hook-and-loop tape.
  

  	Figure I
  	Figure H

  
  

• Now you can dress up the factory foot pedals with some bolt-on pedal covers. Place the new pedal cover over the existing pedal and mark the mounting holes onto the pedal with a silver paint marker (figure H).

• Brace the pedal from behind, and use a center punch to make the divot for drilling (figure I). Keep the brace in place to steady the pedals while you drill the holes.

• Most pedal kits will come with hardware. Use the nuts and bolts provided to attach the pedal cover onto the pedal. Repeat the process for the remaining pedals and you're all set.
  

  	Figure J
  	Figure K

  
  

• Once you're satisfied with the fit and finish of the new floor mats, you want to make sure they are clean and protected. Clean them up with a lint-free rag and rubbing alcohol (figure J). Be sure to remove any fingerprints on both sides of the mats.

• To keep the new floor mats from sliding around on the carpet, stick on some hook-and-loop tape (figure K).

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

Special Resources for Tricked Out, episode 111

Racing Innovations, Inc.
Website: www.racinginnovations.com

StreetGlow, Inc.
Website: www.streetglow.com

Vibrant Performance
Website: www.vibrantperformance.com