Dismiss Notice



Register Today It's free! This box will disappear once registered!

96 sport manual project

Discussion in 'Modified 1995-2001 Explorers' started by mz35z, December 9, 2018.

  • Searches ExplorerForum.com
    1. mz35z

      mz35z Member

      Joined:
      October 7, 2015
      Messages:
      76
      Likes Received:
      11
      Trophy Points:
      8
      Location:
      Michigan
      City, State:
      Hazel Park
      Year, Model & Trim Level:
      1996 Ford Explorer Sport
      Thread for keeping track of my before and afters of my modifications and repairs. I've done quite a bit already to keep this old thing running well. She sat for many years before I got it so most seals we're shot.

      Since mechanical issues are now fixed, ive done a lot of rust work. Almost ready for final paint to go on it.

      For the rust work I am trying two methods, the drivers side was bad so I cut out all rust and added in new panels. Much more labor intensive than the passenger side, but it seems to have turned out better. The passenger side wasn't as bad and I tried an easier (probably more frowned upon) method. All rust was cut out and cleaned off, covered in rust reformer and underbody coating. Then (don't yell at me, it's a test) locktite dense spray foam was used to fill holes. I know that the great stuff foam acts as a sponge, but my idea is: locktite foam is much more dense and water resistant. Also the foam is getting completely coated in underbody.
      In hindsight, I think the idea was sound, but the body work to smooth out the surfave of the foam is much harder than if I would have just put new sheet metal in. I'm thinking in about a year I'll just redo the passenger side the right way. Either way here are pictures.

      Last two pics are the installation of the roof lights. I was debating between putting lights on a rack and finding a way to waterproof the wiring, or just mounting right to the roof and wiring inside the cab. The ladder option was the best. Waterproof butt splice connectors used. Fused at 30 amps but after calculating, it would be better suited for a 20 amp fuse.

      If anyone has followed my journal this far, let me know what you think!

      IMG_20181120_164009.jpg

      IMG_20181123_202531.jpg

      IMG_20181208_190308.jpg

      IMG_20181208_190648.jpg
       
      • Like Like x 1
    2. Support EF

      Join the Elite Explorers for $20

      Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.


      to hide adverts.
    3. imp

      imp Elite Explorer

      Joined:
      November 12, 2009
      Messages:
      4,030
      Likes Received:
      330
      Trophy Points:
      103
      Location:
      West-Central AZ along the Colorado River
      Year, Model & Trim Level:
      59 Ranchero F250 D'Line
      @mz35z Formidable undertaking! Will look forward to seeing progression of your work. Thanks!
      imp
       
    4. mz35z

      mz35z Member

      Joined:
      October 7, 2015
      Messages:
      76
      Likes Received:
      11
      Trophy Points:
      8
      Location:
      Michigan
      City, State:
      Hazel Park
      Year, Model & Trim Level:
      1996 Ford Explorer Sport
      I will keep posting updates, paint and new window tint and I'll be done for the time being... But the project never ends. Haha
       
    5. WormsExplorer

      WormsExplorer Elite Explorer

      Joined:
      February 14, 2015
      Messages:
      948
      Likes Received:
      228
      Trophy Points:
      53
      Location:
      Colorado Springs, CO
      City, State:
      Colorado Springs, co
      Year, Model & Trim Level:
      98 4.0 ohv sport 5
      Did you just cut out the Rocker panel and leave it at that. I also look forward to more updates on your Sport.
       
    6. WormsExplorer

      WormsExplorer Elite Explorer

      Joined:
      February 14, 2015
      Messages:
      948
      Likes Received:
      228
      Trophy Points:
      53
      Location:
      Colorado Springs, CO
      City, State:
      Colorado Springs, co
      Year, Model & Trim Level:
      98 4.0 ohv sport 5
      Well if I read the whole post I would have read what you did LOL. My Bad for asking a silly question.
       
    7. Hacra

      Hacra Member

      Joined:
      May 30, 2014
      Messages:
      72
      Likes Received:
      10
      Trophy Points:
      8
      City, State:
      Helsinki
      Year, Model & Trim Level:
      1997 5.0 Eddie Bauer
    8. mz35z

      mz35z Member

      Joined:
      October 7, 2015
      Messages:
      76
      Likes Received:
      11
      Trophy Points:
      8
      Location:
      Michigan
      City, State:
      Hazel Park
      Year, Model & Trim Level:
      1996 Ford Explorer Sport
      Currently waiting for the new paint to dry. It's tractor paint, but hey. I saved money and I have time to wait for it to dry. Turned out very well. I may clear coat so I don't have to maintain a matte paint, but I'll have to wait a while longer for the alkyd to dry all the way.

      Snapchat-1977027090.jpg

      Snapchat-809483112.jpg
       
    9. WormsExplorer

      WormsExplorer Elite Explorer

      Joined:
      February 14, 2015
      Messages:
      948
      Likes Received:
      228
      Trophy Points:
      53
      Location:
      Colorado Springs, CO
      City, State:
      Colorado Springs, co
      Year, Model & Trim Level:
      98 4.0 ohv sport 5
      That looks really good. Is that a rattle can job?
       
    10. mz35z

      mz35z Member

      Joined:
      October 7, 2015
      Messages:
      76
      Likes Received:
      11
      Trophy Points:
      8
      Location:
      Michigan
      City, State:
      Hazel Park
      Year, Model & Trim Level:
      1996 Ford Explorer Sport
      Thanks! And it's just a $15 'sprayit' gun from home deopot. Yenkin Majic tractor paint.
       
    11. mz35z

      mz35z Member

      Joined:
      October 7, 2015
      Messages:
      76
      Likes Received:
      11
      Trophy Points:
      8
      Location:
      Michigan
      City, State:
      Hazel Park
      Year, Model & Trim Level:
      1996 Ford Explorer Sport
      Here are some pics after adding a clear coat. The matte finish just wasnt strong enough, so I picked up some alkyd clear enamel. $60 in tractor paint later and I'm good!

      Right now I'm seeing some slight orange peel, but I'm hoping it dries just like the green base coat. I'm happy with how it looks as of now though.

      Snapchat-1668483154.jpg
       
    12. WormsExplorer

      WormsExplorer Elite Explorer

      Joined:
      February 14, 2015
      Messages:
      948
      Likes Received:
      228
      Trophy Points:
      53
      Location:
      Colorado Springs, CO
      City, State:
      Colorado Springs, co
      Year, Model & Trim Level:
      98 4.0 ohv sport 5
      WOW that does look awesome.
       
    13. mz35z

      mz35z Member

      Joined:
      October 7, 2015
      Messages:
      76
      Likes Received:
      11
      Trophy Points:
      8
      Location:
      Michigan
      City, State:
      Hazel Park
      Year, Model & Trim Level:
      1996 Ford Explorer Sport
      Thanks!!

      Got it outside to bake the paint a bit
      This tractor paint is awesome but man does it take forever to dry.

      IMG_20190105_124926.jpg
       
      • Like Like x 1
    14. masospaghetti

      masospaghetti Well-Known Member

      Joined:
      October 22, 2006
      Messages:
      1,139
      Likes Received:
      18
      Trophy Points:
      48
      City, State:
      Huntington Beach, CA
      Year, Model & Trim Level:
      98 XLT, OHV, 4D, 4x4, 5M
      Looks nice! How does the tractor paint hold up to chemicals / gasoline? I did a Rustoleum roll on job on a Fiero once, and it looked decent, but the paint faded quickly and gasoline would dissolve it.
       
    15. mz35z

      mz35z Member

      Joined:
      October 7, 2015
      Messages:
      76
      Likes Received:
      11
      Trophy Points:
      8
      Location:
      Michigan
      City, State:
      Hazel Park
      Year, Model & Trim Level:
      1996 Ford Explorer Sport
      I have read from the manufacturer that it holds up well. Even better with a hardener added to the paint. I will test on some metal I painted in my garage what happens when gas/oil etc gets on it
       
    16. WormsExplorer

      WormsExplorer Elite Explorer

      Joined:
      February 14, 2015
      Messages:
      948
      Likes Received:
      228
      Trophy Points:
      53
      Location:
      Colorado Springs, CO
      City, State:
      Colorado Springs, co
      Year, Model & Trim Level:
      98 4.0 ohv sport 5
      I really like how it turned out.
       

    Share This Page







    We Support Our Troops!