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Rebuilding a 2nd gen Explorer with a 1st gen rear clip

Discussion in 'Modified 1991-1994 Explorers' started by CDW6212R, November 11, 2005.

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    1. Charlie's_93EB

      Charlie's_93EB Cat 3 Hurricane Rated

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      is this a right hand drive? Are the main switches on the pass side b/c you are a mailman?
       
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    3. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      It's still left hand drive, I just have mounted switches on the right for turn signals, windows, mirrors, and strobes. I will finish an onboard air compressor last, and have more work space when finished.
       
    4. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Here are a few wiring pictures from last Fall.
       

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    5. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      More wiring, both for the OEM ARC shocks, and auxilliary circuits.
       

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    6. Burns

      Burns Elite Explorer Moderator Emeritus

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      thats a lot of wires....
       
    7. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      This is from final wiring the electric fan, and the ARC shock height sensor. I elongated the frame holes to adjust the rear ride height. With 1" blocks in back, one torsion bolt out and the other set for level, I have it lower than stock, but not exactly what I had in mind.
       

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    8. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I have been busy, but I have been driving this truck. The odometer worked fine for ten miles, then it began quiting every once in a while. I counted miles, I know generally how far every trip I make is, pulled it back out and looked it over, adding the needed miles. After that made no difference, I changed the whole speedometer as a unit. It is good now, and the speedometer is really close also. I'll put the back interior back into it today.
       

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    9. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I have to drill new holes for the front fender flares, there are 95-98 flares and 98-01 flares which take different fender holes. The air tanks, lines, and running boards will be last to do, but it is a nice driving truck as it is. I'll drive it until the 16" tires are worn out, then decide about the height again. If it has any bottoming out now when loaded, then the back would be high enough. Hopefully the ARC shocks will let me drop it another 1/2" or so in back, the front could go down another inch easily. Regards,
       
    10. Dre

      Dre Elite Explorer

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      That front clip looks like it's darker... or is it just me?
      The whole thing looks a bit strange now... combo - first and second gen. kind of cool. Get the best of both worlds, right?

      BTW. I converted rear end of my 94 Limited to accept 97 tails... cutting the rear quarters.

      I admire your wiring work... that was most likely pretty painful to put together...
      :thumbsup:
       
    11. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      Man oh man how does it drive? Its been ALOT of work! Congrats!! That is one sharp and customized ride for sure
       
    12. Explorer93RDB

      Explorer93RDB Active Member

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      Wow fantastic Job. I wish I had your patientce , I am installing a 5.0 out of a bird Into my 94 gen 1 Sport, just so I can have the V-8 Sound I had too many 6 cylinder machines and miss my V-8's The EFI wiring swap is driving me crazy. but If I ran one wire at a time it would not be a probem..

      Love the Paint Color .. Now that you are finished with the lift can I come get it and use it to do mine..? LOL I only need it long enough to do a Body off restore..
       
    13. Mud Bug 94

      Mud Bug 94 Well-Known Member

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      my god....i just read the whole thing and while confused as to why...i am impressed with the work..
       
    14. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      You have a good eye, yes the new paint is slightly off, of course. The original paint was new base/clear from 2000. This new paint is a single part, not planned, but no big deal since this is a work vehicle. That last angle shows the color difference better than most views. I still need to remove the tail lights and finish the front edges, filing and painting.
       
    15. techboj

      techboj Active Member

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      Impressive would be an understatement !

      Wow !:chug:
       
    16. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Thanks guys, and Jamie, the ride of the truck is very tought, like my Mountaineer used to be. I hit 99 the other day just for stress testing, I haven't had any hint of mechanical troubles. I plan to start delivering withg it Tuesday, after swapping tires/wheels. I'll take more pictures with the interior almost finished. When done, I'll have more space for storage of tools and work supplies, and the same open area for mail. Every feature works so far, I haven't finished the air supply system yet though.
       
    17. Arthur

      Arthur Active Member

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      i bet you had a lot of fun with that wiring
       
    18. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Basically my wiring was three projects. I dissected a stock 98 Limited harness to remove the ARC air system, I added circuits for my mail vehicle features, and I retrofitted a 2000 EB body harness.

      My 99 OEM body harness had been cut twice, at the left seat and kick panel, so it was unuseable. The only issues I had were because of the difference between the body harnesses, different features of the two. I had to add a wire for the memory seat to GEM module, and the EB harness didn't have the memory seat module power wire(it runs to all mirrors from dash). I tapped that wire into the main seat power wire.
       
    19. Arthur

      Arthur Active Member

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      damn dude... wiring is my least favorite job but my friends are always getting me to do it for em... last summer i bought a quick stripper from sears and its the best one ive ever had and it was only 25 bucks... that made works way easier but regardless wiring still sucks
       
    20. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Wiring using factory wires and connectors is extremely time consuming. Each of the doors took about two hours to add just the two relays. I cut extra relay leads from spare harnesses, and spliced into all of the window wires at one point. I'm very proud to have all of the windows work as planned, they did need some lubricating(WD40). I can open all windows from each front door, left and right have auto down modules.

      I still need to isolate the mirror switches from one another, they cannot be used while both are connected. More relays will be needed.
       
    21. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      come on guys wiring isnt THAT bad :) hahaha

      I have more hours in my wiring then I do wrenching I think, but its oh so worth it!
       
    22. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I also had to figure out how to send signals to the rear speakers, because full console models have those going through the console wiring. I located those eight wires in the center harness(console), and cut/spliced them in pairs. The Kenwood which I bought for the work vehicle has now been in my 95 Crown Vic, the 93 Explorer, and this 99. It sounds much better now with aftermarket speakers.
       
    23. bikeboarder

      bikeboarder Active Member

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      wow, that looks sweet. ford should make an explorer like that. maybe a designer will take some notes. i hate the soccer mom explorers that they are puting out now.
       
    24. Dre

      Dre Elite Explorer

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      and yet I love to play with the wires in my truck... always putting extra circuits, rewiring stuff... but I really admire what you've done... working power window controls on both doors? that's one custom rig... :confused:
       
    25. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I had certain issues of course to deal with. This pictures is of the rear center seat belt hold down bolt. It stripped with my Snap-On T50 bit, and I ended up having to drill almost completely through it. Vise-grips and a hammer with chisel didn't loosen it. Only after drilling it through with a large bit could I carefully chisel out the threads.
       

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    26. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      seat belt bolts on Fords = PITA
      I keep a spare T-51 bit around now, they just twist and strip because the bolts are FROZEN
      Thank goodness I seem to remove seats and stuff yearly so they dont get a chance to rust in place anymore
      At the junk yard one day myself and two buddies had the entire interior of a 90 BII stripped out in about 30 minutes (hand tools) then we spent 2 hours on one seatbelt bolt
      PITA
       

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