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Edited: Nov 11, 2021

Explorer Sport Redux

Was a prior member/inmate here several years ago, but after my '91 Explorer Sport was totaled in a commuting accident, kind of fell away from the 4x4 and overlanding scene. Fast forward a few years, after storing the remnants of my rig at a buddy's shop and looking for a "pandemic project" stumbled across a 1994 2 door with only 83,000 miles, manual transmission, and way-too-clean interior - - for a miserly price of $2,900.00. Simple plan - take all the good stuff off the old Sport and swap it onto the new(er) one; of course, not much is "simple" when taking multiple bits and pieces off one nearly 30 year old vehicle for another. Added to the mix was some other drive-line parts from another donor rig. . . and you get the idea.

(Edit: Just wanted a better "money" shot for the lead-in to this thread)

The new-to-me rig, homecoming (May 2020)

Here's the list of the major components that have immigrated to the new Sport:

1) Atlas transfer case, 4.3:1 gear ratio,

2) ARB Air Lockers, front: Ford Dana 35TTB, rear: Ford 8.8 with disc brake upgrade, both 4.56 gearing,

3) James Duff extended radius arms, F-250 front shock mounts (major articulation increase),

4) Spring over rear suspension with extra leaf,

5) SuperLift suspension components and front coils, SuperLift Super-Runner steering,

6) James Duff front bumper with Warn fog lights and "hidden" Ramsey REP 8000 winch,

7) Custom rear bumper with full-size spare, "frenched" license plate holder into hatch

8) Goodyear MTRs, 33 x 12.5 x 15,

9) Rancho shocks,

10) Outback Solutions rear drawer system,

11) Bushwhacker Extend-a-Fender flares,

12) Custom rocksliders, rampsliders, and diff protection,

13) Custom "visor shelf" for storage and switch panel.

Field test, Moab, UT (May 2021)

Recent run up to Lonesome Lake and the Rainier Viewpoint (November 21)

Happy Trails.

Paul

6 comments

6 Comments

Grit City Paul

Mar 09, 2022

Finally dug out a a set of Rigid Industries LEDs that was sitting in storage box after swapping out most of the gear from the wrecked Sport to this rig. Had these mounted to the Con-Ferr roof rack on the old Sport, but no plans to the roof rack on this vehicle (so far).

Fit almost perfectly in the void between the tubes of the James Duff bumper:

Paul

Grit City Paul

Dec 30, 2021

Thanks for the comments, the first generation Explorers were pretty capable, certainly compared to the later versions. Even the D35 TTB (Twin Traction Beam) front axle isn't a bad set-up, especially if you keep the tires at 33" or less. Greatest limitation up front is the articulation - - solved by welding F-250 shock towers to the coil buckets to greatly improve droop.

Hard to see, but modified shock tower coil bucket:

James Duff Radius Arms obviously an improvement over stock:

Hardest thing about building an older Explorer is parts availability. . . Aftermarket gear for the first generation was limited, and dwindled to nothing with the subsequent generations that came later. Much different landscape than that for Jeep or Tacoma owners, but I like the challenge. "Super-Unobtanium" SuperLift SuperRunner Steering really improves the geometry over stock, luckily can still purchase the bushings from SuperLift.

Paul

jcadcars1492

Dec 29, 2021

Very capable rigs. Great turning circle if I remember correctly.

Grit City Paul

Nov 11, 2021

Some exterior shots:

Duff front bumper, Warn fog lights. . .

Ramsey "hidden" winch, fairlead, Duff skid plate and D35 armor. . .

Bushwhacker Extend-a-Fender flares, rock sliders, rear leaf "ramps". . .

Rear bumper with the way huuuuuggee 33" MTR and "frenched" license plate into the rear hatch. . .

Back-up lights mounted into the rear bumper. . .

Roto-Pax fuel cell mounted in OEM spare tire mount location . . .

Paul

Grit City Paul

Nov 10, 2021

Yep, a little forced perspective I'd guess. . .

Some interior shots:

Overhead switch panel, mounted on visor shelf - - panel includes extra interior dome light, forward fog lights, rear back-up lights, and ARB switches (compressor, rear, front)