Hey guys! I know im new to the forum but i have been looking at all the amazing projects that have been done and decided to join The title says it all, but i was siting around one day and wondered how cool illuminated door sills would be so i went to work! I looked a bit and didnt see any for my 09' so i decided to make my own using my door sill, a dremel tool, and some good ol' EPOXY! As of right now the F is complete and the O is half way done but i ran out of epoxyD: a quick drive tomorrow to the local home depot will fix that. But as soon as i figure out how to post pics i will show you how im doing it. Anyone with a dremel tool can do this. Ive also read heating a kitchen knife over an open flame is handy too. The only things you need is confidence and a good eye for detailing. Hope to post pictures tonight! If you have any questions just ask:]

 

cant wait to see them done

 

I still dont know how to post a picture on the thread but i have put some pictures in my gallery

 

The Picture Speaks for itself i do believe! This is a sneak preview of what is to come......tomrrow, haha its late so here is my progress for today The F is full of epoxy and frosted wheras you can tell the O is only half filled and not frosted, you can see through it and see the actual LED bulbs and wires

 

Looks great so far! Can't wait to see it complete. How do you plan on wiring the LEDs?

 

The LEDs are ready to be wired to a 12V so i am going to connect to the lights that are on when the doors open, if i can find one, if not then I know the dome lights will work

 

There's a wire in the door step plate that switches when the doors open. Could have been the door trigger. Don't remember.

 

are you getting it done we want pics & how tos

 

please take some good pics and do a how too this is pretty cool

 

I went after work and got some more eopxy! I like this exact package because it has a syringe for precision and it mixes the components in the syringe so you just push and aim

This is the dremel, and the 3 bits im using, the bit on the left is what i use to take out chunks and make a straight edge. The right bit is a cone shaped, i use this for the curved edges. The bit on the dremel is tightly packed fibers, it sands the inside so it looks smooth

These I found at autozone for $15, they are 12" long and are as bright as i could find.

I was grabing a snack and saw this wax paper siting on my pantry shelf, and i thought to myself that this would add the slightly frosted look i need so the epoxy isnt completely see through! Ill figure out how to attach it securely after im completely finished.

These are the tools i use in this project. So I i cut away as much of the plastic with the circular dremel bit, leaving a little space between the edge of the letter. I use the same bit to cut to the edge for straight edges ONLY!!! I use the cone shaped bit to carved the curved edges, it gives more precision, careful though, it will eat through plastic once it heats up a lot very easily. Remove any platic that hanging on the plate, you always need so see exactly what your cuting. This shiiit that hanging is actually melted so let it cool for a couple seconds or blow on it. I just burnt my finger and it hurts....Once the letter is cut out i sand it very lightly to make it smooth because epoxy is completley clear and you will see imperfections. To amply the epoxy, you need something to keep the epoxy inside the letters until it dries so i used 3M clear packing tape because it sticks to the back of the plate very well. Once its sanded brush away all the dust and plastic you dont want on the final product. apply the epoxy in the cavity and apply slowly so you can get a flush finish. My epoxy is cured and its just as hard as the plastic itself so no worries its strong. The Letters ORD have pieces that will need to be put back in middle to make it look like a letter. I sanded these pieces of plastic down so they are smooth and after i applied the taep to the back of the plate, i centered the cutout on the tape and filled the epoxy in the spaces around it. Thats pretty much all i can think about right now. If you do this, make sure you wear eye protection, plastic flies around and can hurt your eyes, the dremel must be at a fast speed but cut slowly, precision is a must. Keep a firm grip on the dremel, seriously, FIRM! One slip can put a nasty gash in you plate. It takes a while but it will look badass when its done! Any questions just ask! Oh and Im charging the camera battery, more pics up, hopefully finished, by tonight

 

looks good, you dont have footwell lighting do you? that would be sweet to tie into those!

 

No i dont:/ I wish i did, i imagine how easy it would be then, but so far the R has been the hardest most detailed letter, im going to cut the letter D, Put Epoxy in it, take more pictures of course and i should have it in the truck, hopefully wired, tonight

 

Nice work so far, keep us posted

 

subscribing!!! good luck man.

 

Finished cutting out the letters

Just be careful not to destroy this clip although some epoxy will keep it in place if any mishaps occur

This stuff you have you have to pull off, It cause the bit to jump a bit and just looks ugly.

Keep the tape nice and tight and seal the corner near the yellow clip so epoxy doesnt ooozzz out.

Just apply one even coat until its flush, do it slowly because it expands just a little but it dries in 5 so you have 3 to apply it. If there are any imperfections, it dries in 5 mins so just apply more epoxy to the uneven spots.

And DO NOT rip off the tape!! idk if you can do it after 24 hours once the epoxy is fully cured but in this stage it will pull out the epoxy. Just do a nice trim

Im going to epoxy the D and then go find the wire i will tap into for the LEDs. Any help would be great! I need to find a wire that turns on when i open the door, i know theres the dome lights but something closer would be wonderful. I have tons of wires under the door sill and dont have a clue which one to connect to:/