1. Holiday Special! - 2 for 1 Elite Explorer sale!

    Right now you can purchase an Elite Explorer membership for $20 and receive a two year membership!

    Click Here to start your membership and get rid of the ads!

    Dismiss Notice
Dismiss Notice



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

"Blue Bandit" (1992 Eddie Bauer)

Discussion in 'Elite Explorer Registry' started by NICE59FORDF100, April 22, 2004.

^^Searches ExplorerForum.com^^





  1. cybergasm

    cybergasm B

    Joined:
    January 8, 2006
    Messages:
    6,487
    Likes Received:
    1
    Trophy Points:
    0
    City, State:
    Humboldt Ks
    Year, Model & Trim Level:
    1997 Mountaineer 5.0
    hmmm don't think you can paint Blue now.....it would lose it's charm.
     
  2. Support EF

    Elite Explorer 2 for 1 Sale! $20 for 2 years!

    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.



  3. NICE59FORDF100

    NICE59FORDF100 Staff Member Moderator Elite Explorer

    Joined:
    June 3, 2003
    Messages:
    3,306
    Media:
    1
    Albums:
    2
    Likes Received:
    28
    Trophy Points:
    68
    City, State:
    Austin, TX
    Year, Model & Trim Level:
    OBD-1 Kenobi
    Well, in the same weekend, i also did some major body changes inside blue. First was finding a new location to mount the EEC-IV PCM, since with the 5r swap, the extra wire make it nearly impossible to mount it in the stock location in the kick panel. So i located a good spot which happened to be right under the passenger seat. Problem is there is pesky metal in the way...SO i started cutting
    [​IMG]

    and more cutting
    [​IMG]

    so my plan is to box in the hole i cut out, and recess the pcm down into the floor. SO i started making the templates
    [​IMG]

    then I made the pan portion of the box (out of original metal nonetheless, lol)
    [​IMG]

    And finished welding in all the sides
    [​IMG]

    and it fits!
    [​IMG]

    It will have sealer put on all the seams and lined with that grippy felt stuff to help isolate it from the body. then the carpet will slip over it and hid it completely! SO thats one task out of the way. Next up, adjustable seat belts!
     
    Last edited: December 5, 2012
  4. MrQ

    MrQ Fuel Pump Replacer Elite Explorer Moderator Emeritus

    Joined:
    October 5, 2008
    Messages:
    2,709
    Media:
    18
    Albums:
    2
    Likes Received:
    187
    Trophy Points:
    83
    City, State:
    Houston, TX
    Year, Model & Trim Level:
    '93 Limited
    Lookin good!
     
  5. NICE59FORDF100

    NICE59FORDF100 Staff Member Moderator Elite Explorer

    Joined:
    June 3, 2003
    Messages:
    3,306
    Media:
    1
    Albums:
    2
    Likes Received:
    28
    Trophy Points:
    68
    City, State:
    Austin, TX
    Year, Model & Trim Level:
    OBD-1 Kenobi
    Thanks Dan! And to he who asked, I will not be painting Blue at this point, all Im doing it trying to get the truck roadworthy again, and the interior is only stage one. Stage two of the overhaul is suspension work lol
     
  6. NICE59FORDF100

    NICE59FORDF100 Staff Member Moderator Elite Explorer

    Joined:
    June 3, 2003
    Messages:
    3,306
    Media:
    1
    Albums:
    2
    Likes Received:
    28
    Trophy Points:
    68
    City, State:
    Austin, TX
    Year, Model & Trim Level:
    OBD-1 Kenobi
    Guess who has adjustable seat belts!? This guy :) pics later hehe
     
  7. TexasArmadillo

    TexasArmadillo Active Member

    Joined:
    June 1, 2010
    Messages:
    450
    Likes Received:
    0
    Trophy Points:
    16
    City, State:
    N 29.554349 W 95.295959
    Year, Model & Trim Level:
    10' Explorer XLT
    Good to hear bud. I have to go to Oklahoma City on the 30th. If your around I'll swing by and say hello.
     
  8. NICE59FORDF100

    NICE59FORDF100 Staff Member Moderator Elite Explorer

    Joined:
    June 3, 2003
    Messages:
    3,306
    Media:
    1
    Albums:
    2
    Likes Received:
    28
    Trophy Points:
    68
    City, State:
    Austin, TX
    Year, Model & Trim Level:
    OBD-1 Kenobi
    Absolutly bud!! Youre always welcome here!!
     
  9. NICE59FORDF100

    NICE59FORDF100 Staff Member Moderator Elite Explorer

    Joined:
    June 3, 2003
    Messages:
    3,306
    Media:
    1
    Albums:
    2
    Likes Received:
    28
    Trophy Points:
    68
    City, State:
    Austin, TX
    Year, Model & Trim Level:
    OBD-1 Kenobi
    Ok, so in the midst of updating interior stuff in Blue, i decided i wanted to add these:
    [​IMG]

    So in order to do that, i had to pull metal from the mountaineer i chopped up to figure out how to intergrate adjustable seatbelts into a first gen. I know Ghosttrain had drilled out the skin and weld it back in with second gen skin, so that was the plan
    [​IMG]

    So after drilling out the spot welds, i also pulled out the inner support that has the anchor points behind the skin
    [​IMG]

    you'll notice the there is a hole in the center that the factory first gen seat belt attaches to, and they line up perfectly. This aided in aligning the anchor points in the B pillar. So my plan changed to just using the anchor points above instead of welding in the whole skin (more on this later). So I THOUGHT i could get away with this. I was half right.

    So after several test fits and trials, i wouldnt be able to use the entire piece and graft it in. SO i cut off the upper and lower anchor points and proceeded to weld them directly to the original pillar skin. Some hammering and 1" drilling was required to sit the anchor points flush in the skin in order for the final trim piece to sit flush and not bind.
    [​IMG]

    after getting them welded in, i bolted everything back up and success! it fits and doesnt bind!

    Fully up..
    [​IMG]

    Fully down..
    [​IMG]

    and sitting pretty in a first gen :)
    [​IMG]

    so the passenger side is done and now i know what needs to be done and what doesnt. The driver side will go faster, and ill take more pics then.

    NOTE: I know messing with seat belt anchors is a big deal, and the more correct way would be to graft in the skin of the donor vehicle, HOWEVER, my welds are strong and secure, and the slide mechanism will fail first before my welds do. I trust my welding, as i am obviously putting my life on it if the unfortunate ever does happen.
     
    Last edited: December 5, 2012
  10. NICE59FORDF100

    NICE59FORDF100 Staff Member Moderator Elite Explorer

    Joined:
    June 3, 2003
    Messages:
    3,306
    Media:
    1
    Albums:
    2
    Likes Received:
    28
    Trophy Points:
    68
    City, State:
    Austin, TX
    Year, Model & Trim Level:
    OBD-1 Kenobi
    so we last left off with the install of the adjustable seatbelt on the passenger side. The next project on the list was the PRND21 gauge indicator modification to fit my 5R55E swap for the gauge cluster. First gen indicators have the P R N OD D 2 1 setup and it is no longer needed because of the O/D cancel switch in the gear lever. SO I started modifying. Kris Guilbeaux was kind enough to give me a white face PRND21 indicator from a 2001 sport. So I started comparing the two
    [​IMG]

    The mechanisms are considerable different as you can see, so it would not just bolt in. SO i compared the paper themselves...
    [​IMG]

    Ah, not so different, just some trimming needed. So i placed the PRND21 paper in the first gen housing and volia! Damn near perfect
    [​IMG]

    So after a bit of trimming and positioning, I had it nice and installed and sitting pretty. Keen eyes will noticed I even modified the second gen needle to fit the first gen mechanism for a bit more updated look.
    [​IMG]

    And here it is installed in the cluster with the old gauges and bezel. Looks good if i do say so myself
    [​IMG]

    Also redid the needles since they faded
    [​IMG]

    Now some of you may ask what about adjustment and needle placement once in each gear? With the new indicator, i did have to adjust the gear wheel to get the needle lined up, but once adjusted, it moves perfectly with the gear lever. Speaking of which...
    [​IMG]

    The top is the second gen gear lever, the bottom is a first gen. As you can see, quite a bit of different and not a simple swap over. So time to bust out the welder. First I had to get the angle just right, and this took a few tries to do so
    Here I welded the first gen nipple to the approx placement on the second gen stalk to get it located just right
    [​IMG]

    After i got it in the right place, i welded it on up, grinded smooth, and ready for paint and install
    [​IMG]

    Here is the combo installed and aligned correctly. Looks stock, just like it should.
    [​IMG]

    About this time, a huge box came in the mail and to my delight and surprise, a special someone bought a little christmas present for Blue...NEW FREAKING LIMITED DOOR PANELS!!!
    [​IMG]

    These panels were manufactored replacements, meaning they have never been installed on a vehicle, ever. Perfect NOS examples...Thank you again for the awesome gift!!!!

    (Side note) Since I had installed the one touch down relay for the passenger door, there was no place to mount to the door panel like the driver side...or so i thought. One simple bend later, and i was able to screw it in with the arm rest just like the driver side
    [​IMG]

    So i finished up the doors as far as wiring and fixing the door lights, and installed the passenger side...OMG, it looks so amazing in person
    [​IMG]

    The driver side even came with a brand new memory switch...this will come in handy later...
    [​IMG]
    [​IMG]

    My next project was yet another gift from Kris G. (youre too kind to me sir) which was a 94 navajo cluster with 6 digit odometer. Problem was, it was sitting at 147K miles, where as blue is at 271K miles. So after an hour trying to get it apart to reset, i just gave up and decided to travel the difference in miles...with a drill...
    [​IMG]

    So 2 hours later, travelling 100 miles every 20 second or so, i got to my right mileage and installed
    [​IMG]

    Also with the navajo cluster was the faux carbon fiber bezel which i will be using with the New white face gauges i ordered.
    [​IMG]

    I also took this time to run the wiring for the OBD-II DLC (Data Link Connector) for the 5R55E trans, as well as for the OD cancel switch
    [​IMG]

    While I was under here, i also added a RAB Test circuit Contact Switch to the glove box.
    [​IMG]

    What this does, just like my OBD-I test switch to the left, is when pressed, it temp grounds out the RAB test circuit, thus pulling the codes for the ABS without having to get under the dash with a ground wire. Blue has been having interemittent ABS lights coming on, so next time it does, I want to be ready for it :)

    Again, while i was under the dash, i decided to wire in the memory seats. The seat is from a 2000 Limited, so it is tied into the OBD-II ISO multiplex communication network, so i ran the wire to the DLC for that, and, thanks to Blueka, wired up the limited seat connector that goes through the carpet. Thanks again Simon!!
    [​IMG]

    Once that was done, time to test the seat out...turns out it works quite well :D
    [​IMG]
    [​IMG]

    About this time, my new white face gauges arrive (finally!) and so i installed them real quick, seeing as i prewired it behind the cluster
    [​IMG]

    Im still on the fence on how i like them, but i suppose they will do for now. At least they work, something the old ones had a problem with accomplishing :rolleyes:
    [​IMG]

    Then that brings us to now. New years weekend. Since yesterday was so pretty (almost 70's) I decided it was time to install the power sunroof. Having kept the roof metal from the 97 mounty i chopped up earlier this year, I had everything I needed to install a second gen sunroof into a first gen
    [​IMG]

    The first thing I did was seperate the rear roof crossmember and install it in place of the one in Blue. The difference is the screw holes that anchor the rear of the sunroof to the roof. However, both units are stamped the same, and after drilling out a couple of spot welds, it slid right back in. Once the sunroof is installed and flush, ill weld it in to get proper adjustment. I also extended the first gen dome light dome light bracket and installed it.
    [​IMG]

    Then it was time to prep the roof metal. Since the rear crossmember fit right in place, i didnt have to cut as much out as I thought. Since I havent seen anyone else attempt this, i was kind of just guessing as i went along, LOL
    [​IMG]

    Side note: Hoodies are extremely flammable while grinding...
    [​IMG]

    I made all my measurements several times, then decided on a cut that i was comfortable welding it and got it prepped
    [​IMG]

    I then made a cardboard templete to get the cut lines on Blue's roof ready...
    [​IMG]

    This was the point of no return. Either I did this right, or got it incredibly wrong. This has to be centered perfectly side to side and front to back. SO after triple checking everything, i got the grinder out...
    [​IMG]
    [​IMG]

    SO after some minor grinding ( i cut the hole smaller on purpose, i fitted the new sunroof metal and bam! Perfect fit!
    [​IMG]
    [​IMG]
    [​IMG]

    So thats where im at now. As soon as i post this, im going to weld the rest of it in, grind it smooth and primer it. Then install the sunroof, get everything aligned, and weld in the inner support beams. SO comment, concern, question, GO!
     
    Last edited: December 5, 2012
  11. reapereviltwin

    reapereviltwin Keep on wheelin John Rock Staff Member Moderator Elite Explorer

    Joined:
    August 17, 2009
    Messages:
    2,217
    Likes Received:
    89
    Trophy Points:
    68
    City, State:
    Glen Rock, Pa
    Year, Model & Trim Level:
    '92 Explorer
    Blue is looking good, Russell !!!!! :biggthump
     
  12. NICE59FORDF100

    NICE59FORDF100 Staff Member Moderator Elite Explorer

    Joined:
    June 3, 2003
    Messages:
    3,306
    Media:
    1
    Albums:
    2
    Likes Received:
    28
    Trophy Points:
    68
    City, State:
    Austin, TX
    Year, Model & Trim Level:
    OBD-1 Kenobi
    Thanks mike! Hes coming along. Hopefully youll see him in person soon ;-)
     
  13. TexasArmadillo

    TexasArmadillo Active Member

    Joined:
    June 1, 2010
    Messages:
    450
    Likes Received:
    0
    Trophy Points:
    16
    City, State:
    N 29.554349 W 95.295959
    Year, Model & Trim Level:
    10' Explorer XLT
    Looks good. I guess you got it all together now and my rain dance failed.
     
  14. MrQ

    MrQ Fuel Pump Replacer Elite Explorer Moderator Emeritus

    Joined:
    October 5, 2008
    Messages:
    2,709
    Media:
    18
    Albums:
    2
    Likes Received:
    187
    Trophy Points:
    83
    City, State:
    Houston, TX
    Year, Model & Trim Level:
    '93 Limited
    Looks good Russell! :thumbsup:
     
  15. NICE59FORDF100

    NICE59FORDF100 Staff Member Moderator Elite Explorer

    Joined:
    June 3, 2003
    Messages:
    3,306
    Media:
    1
    Albums:
    2
    Likes Received:
    28
    Trophy Points:
    68
    City, State:
    Austin, TX
    Year, Model & Trim Level:
    OBD-1 Kenobi
    Why would you want it to rain inside Blue?? :-(
     
  16. NICE59FORDF100

    NICE59FORDF100 Staff Member Moderator Elite Explorer

    Joined:
    June 3, 2003
    Messages:
    3,306
    Media:
    1
    Albums:
    2
    Likes Received:
    28
    Trophy Points:
    68
    City, State:
    Austin, TX
    Year, Model & Trim Level:
    OBD-1 Kenobi
    So the next day I finished up the rest of the welding (which took most of the day) and started on the install of the sunroof.
    [​IMG]

    And volia! It fitted perfectly the first time with no adjustments, yay!
    [​IMG]

    It was at this time i decided to do yet another one of my signature moves and make a small change only I would notice. Since second gen sunroof consoles had a rocker switched that matched the rest of the interior, i decided i wanted to try and match all the first gen switches...so i did :p:
    [​IMG]

    So I ran the wires real quick and ill let the pics speak for themselves...

    Fully closed
    [​IMG]

    Vented
    [​IMG]

    And fully open
    [​IMG]

    I still got some finishing welding to do on the support brackets, but for all intensive purposes, the sun roof is done (finally). What i have learned is i will never do another one of these things again, lol

    While i was at it, i buttoned up all the dash back together and threw on some limited steering wheel covers that are tan in color (not pictured)
    [​IMG]

    So there you have it. I think i got a bit done during my three day weekend. I figure in two weeks, i should have the interior back together and I can start on the suspension bits. Im ready for some good sleep now lol.
     
    Last edited: December 5, 2012
  17. sport97

    sport97 Elite Procrastinator

    Joined:
    September 25, 2008
    Messages:
    2,358
    Likes Received:
    1
    Trophy Points:
    48
    City, State:
    connellsville pa
    Year, Model & Trim Level:
    1997 sport SOHC 4.0
    Wow, you have been a busy man! It looks great! You are a braver man than I for chopping into a roof, but it came out great. I love having a sun roof. My friend has a camaro he had considered making into a t-top car, but none of us are crazy enough to chop into the roof of a car with 50k miles.
     
  18. TexasArmadillo

    TexasArmadillo Active Member

    Joined:
    June 1, 2010
    Messages:
    450
    Likes Received:
    0
    Trophy Points:
    16
    City, State:
    N 29.554349 W 95.295959
    Year, Model & Trim Level:
    10' Explorer XLT
    Well shoot. It seems you have every thing else covered. I want to see if you can deal with flood damage restoration.
     
  19. NICE59FORDF100

    NICE59FORDF100 Staff Member Moderator Elite Explorer

    Joined:
    June 3, 2003
    Messages:
    3,306
    Media:
    1
    Albums:
    2
    Likes Received:
    28
    Trophy Points:
    68
    City, State:
    Austin, TX
    Year, Model & Trim Level:
    OBD-1 Kenobi
    Yea, the whole cutting into the roof thing took me a few minutes to actually start, but once you start cutting, its not too bad. Just gotta have faith in yourself that you measured right, lol. I got lucky and had all the parts available and that helped a great deal. Just plan ahead and know what you want :)
     
  20. NICE59FORDF100

    NICE59FORDF100 Staff Member Moderator Elite Explorer

    Joined:
    June 3, 2003
    Messages:
    3,306
    Media:
    1
    Albums:
    2
    Likes Received:
    28
    Trophy Points:
    68
    City, State:
    Austin, TX
    Year, Model & Trim Level:
    OBD-1 Kenobi
    That dont sound like fun at all!! Boo to that!! Lol. Naw, I try and keep blue away the water, Thats What the navajo will be for lol
     
  21. NICE59FORDF100

    NICE59FORDF100 Staff Member Moderator Elite Explorer

    Joined:
    June 3, 2003
    Messages:
    3,306
    Media:
    1
    Albums:
    2
    Likes Received:
    28
    Trophy Points:
    68
    City, State:
    Austin, TX
    Year, Model & Trim Level:
    OBD-1 Kenobi
    Since I have been working double shifts this whole week, haven’t gotten much done, but last night the new seat belts arrived and I threw them in real quick. These are the 98-01 style with a bit more updated look plus they are cleaner and match the buckles of the limited seats. Im really excited about how all this is coming back together!!
    [​IMG]

    Also, if you scroll back up to the very top post in this thread, I updated with a complete list of modifications and the year vehicles they came out of. Hopefully it’s a complete list, but im sure I forgot something, lol. Either way, enjoy!
     
    Last edited: December 5, 2012

Share This Page







We Support Our Troops!