Paul's '91 Sport

[Paul]

Looking good. I've always liked that you kept the inner panels with your cut doors.

Thanks, I like that they “kind of” look like something that would have come with the rig if those type of doors were an option…

I’m at fault for spending too much time on insignificant cosmetic stuff, but I enjoy the “whole package” perspective when the project is finished.

 

[Paul]

Another snow run, assortment of rigs: Ranger and Jeep on 40’s three Bronco’s on 35’s and me with my “Big Dawg” 33’s. . .

New and old.

40’s, 5L, Atlas…

Fun day . . .

. . . even if I had to practice the occasional “self-recovery”.

Paul

 

[Paul]

3/4 Door Update . . . Still a few months away before I'd consider mounting these, but had the crud for a few weeks so this limited effort (along with some minor Ranger projects) has been enough to keep me busy in the "Man-tuary". . .

After getting all the old paint off, realized there were still plenty of blemishes on the original door skins - - but hey, they're 30 years old. . .

Still a work in progress, but matching the interior taupe/khaki/beige/tan/sand/earth paint keeping me busy.

These door skins were sourced from a lesser trim model Navajo (with roll-up windows - - hole near speaker), but the ones I have on the rig currently have a small map pocket below the speaker so I figured I'd add something like that to these.

. . . and because I just can't leave well enough alone, why not add a fabric panel with some of the leftover fabric from the seat refresh from 2020?

Glued to a fiber resin panel and added some bubble-wrap to give the panel some "heft". . .

Panel construction/gluing;

Getting there. . .

Paul

 

[Paul]

Kinda getting there. . .

Best paint match for the door panels was Rustoleum's Dark Suede, if you're following along. . .

Still not mounting the 3/4 doors before June, but getting the small stuff done . . .

 

[Paul]

Been a minute. . . .

The rig has been "dead-lined" for a few months as I contested with a failed Atlas II with tweaked 25 spline shaft (no longer supported by Advance Adapters) and worked to source both a replacement shaft (more on that below), as well as working with a nearby 4x4 shop to get it installed. Came to learn that in order to make the replacement shaft work, the internals would also need to be swapped, as the internals of my era case were not the same as those from the transfer case I received the near un-obtanium replacement 25 spline shaft from. . .

So . . . long Greek Tragedy backstory aside, I was able to get a fully functional case back and the rig is up and running again.

I want to take the opportunity to thank @gmanpaint for helping out with sourcing the elusive part - - had he not saved that component from his transfer case upgrade, I'd probably have ended up with a nice door stop. . . with "Atlas II" stamped into the side. Also want to thank the members of this site for offering assistance on the "Need an Atlas II" thread with insight and encouragement. Although it's been stated many times by members more esteemed and articulate than I, this site is special. . . Thanks also to Rick and Char for hosting "Serious Explorations" for the last 25+ years. . .

Paul

 

[Rick]

Its really a shame that AA isn't supporting the old Atlas cases. I'm glad you have everything squared away now. It's always great to have contacts.

 

[gmanpaint]

What a PITA to deal with over a single part, you never thought you would have to deal with. In the end, you came out the victor.

Glad I could be of help. Hope you get 20 more years out of that case. Happy Trails!!

 

[Paul]

Its really a shame that AA isn't supporting the old Atlas cases. I'm glad you have everything squared away now. It's always great to have contacts.

It sure is - - halfway considered starting an online petition to have the term "Adapters" removed from the company name since they don't support products that they produced . . . or make an adapter for the products they no longer support.

Glad I could be of help. Hope you get 20 more years out of that case. Happy Trails!!

Thanks, not sure what I'd have done had you not stashed that shaft.

However, while the case was out of the rig, I was not idle. . . In other words, this happened. . .

A list of the upgrades over the last few months:
- Secondary color swap from the Monstaliner gray to dark taupe (aka: tan).
- Reinstalled the Borla headers that used to be on the '91 - - with EGR delete.
- Upgraded wheels and tire package: Goodyear Territory MTs in 315 (35") size on 17" Rough County rims (inner rims painted to match the new secondary color).
- Wireless remote for the Ramsey REP 8000 winch.
- Rear (and forward) "chase" light, just because. . .
- New Mile Marker front hubs.
- Rebuilt transfer case, duh.

Paul

 

[gmanpaint]

35's!! You was already crazy on 33's! Your gonna get into so much trouble now.

Rig looks pretty bad ass! That tan gives it a bit of Dessert Army vibe. Let us know how those tires do over time please.

 

[Paul]

35's!! You was already crazy on 33's! Your gonna get into so much trouble now.

Rig looks pretty bad ass! That tan gives it a bit of Dessert Army vibe. Let us know how those tires do over time please.

Crazy, me ? ? ? I prefer to consider my driving style something more like “controlled chaos” . . .

The tires are take-offs from Kevin’s Bronco as he upgraded to 37’s, so they are not new, just new to me. Already the ride is dramatically smoother, and I had been looking for a less aggressive tire as most of my wheeling is either in Moab or local snow runs. The Bronco guys I know are very complimentary on their performance, and they are very affordable.

The taupe/tan not an intentional homage to either the Army or the 1st Gen “Eddie Bauer” versions of the Explorer, but the Monstaliner gray I used was a mistake, and figured as the interior was beige and brown, it made sense to match that to a color on the exterior. Mirrors, door handles, B,C, D pillars all back to black as well, but some gray remains - - recessed rear license plate housing, radius arms, rear bumper void filler with reverse lights, leaf spring “ramps”, and the compass rose decal on the hood…

Paul

 

[Paul]

Few more pics of the upgrades. . .

The chase/third brake light combo not a necessity, it's made by CookCraft, but if there is a vendor making quality products for our rigs, I'll support them . . .

The amber light is a Baja Designs S2 Sport, and the LED reds are brighter than the OEMs. Since the S2 Sport is a set of 2, opted to put the other one up front. . .

In order to mount the light in the grill, had to add some expanded steel (painted taupe/tan) and some flat aluminum stock to the back of the grill to hold the light mount . . .

Good enough for me. . .

No more room on the switch panel. . .

(Legend: "I" - interior, "F" - fog, "L" - LEDs, "C" - chase, "R" - rear back-up, "A" - ARB compressor, "R" - rear locker, "F" - front locker)


New hubs. . .

Paul

 

[Paul]

As expected, a "smidge" of front fender trimming was required - - no issues with normal road conditions, but disconnect the sway bar and flex it a bit and there was some definite rubbing. . . Instead of self-clearancing, opted to trim the backsides of the front fenders.

Little bit of hose (split) to keep the cut edge of the metal from hitting the tires or (soon-to-be-mounted) fender flares.

(Held on with a liberal application of RVT)

The Bushwhacker Extend-a-Fender flares already trimmed to assist wheel movement.

A bit of the inner fender well also trimmed, no pics. . .

Paul

 

[Paul]

Well . . . this happened. . .

. . . just took 5 years.

If you've been following along (I mean, it's only 13 pages of posts. . . ), when I had these doors on the '91 Sport I had added a Bronco emblem as a tribute to the Explorer's roots - - but that was a time well before the re-launch of the Bronco line. . .

. . . also added the "3", as there was already the Bronco II, so figured the "3" was the next logical number. No intent to pass off that rig as a Bronco, just more of an homage to the bloodline. . .

With the new Bronco's out and popular, there was no way I was going to put a Bronco badge on these doors, so found some Explorer emblems that I'm guessing were knock-offs for the older F-100 pick-up trucks that were listed with the "Explorer" option. A good compromise, in my mind. . .

Finished door card. . .

Windows still solid, in their soft bag since 2016. . .

Paul

 

[410Fortune]

Man that thing could really use the updated side mirrors

Love the tires,
Flares and doors! Well done
My bii will see some sort of half door or fiberglass door insert eventually!

I see the Square mirror mod in your future… once you have them on your rig the old little round ones just look silly

 

[Paul]

Man that thing could really use the updated side mirrors

I see the Square mirror mod in your future… once you have them on your rig the old little round ones just look silly

Thanks, these 3/4 doors really set the rig apart - - even guys that don’t necessarily like Fords can’t help but compliment the rig when they see them. Beside looking good, they really let me lean out of the rig to check tire placement and line selection when off-roaring.

Saw your mirror mod - - intriguing, but no wiring to these doors (other than speaker wire), and really no place on the door cards for a switch / controller to operate them. . .

Round mirrors and square headlights - - I’ve come to accept them as snapshots of the era from when the rig was made - - that’s one of the reasons I still run the Warn fog lights up front - - not great on illumination, but they sure look “period correct”. . .

 

[410Fortune]

The square mirrors on my ranger are manual operation … the electronic control is optional….

 

[Paul]

Wait a minute . . . This isn’t Moab . . .

. . . Stay tuned. . . and I realize the “smart money” would be to not post any pics until making it through the trail, but what the Hell. . .

Paul

 

[Paul]

Welp . . . , not as planned.

Rear axle (driver side). . .

Front hub. . .

Creative fabrication (front axle “ear”). . .

Turned back before Buck Island, one vehicle went into “limp mode”, but I had already exhausted my spares, so we headed back the way we came.

“Redemption Run” planning already underway…

Paul

 

[Kirby N.]

That trail is rough. It’s weird how slippery the rocks are with dust on them. Sorry you broke dude! That isn’t just one break- that’s both ends! Probably best to turn back before the sluice.

 

[Paul]

That trail is rough. It’s weird how slippery the rocks are with dust on them. Sorry you broke dude! That isn’t just one break- that’s both ends! Probably best to turn back before the sluice.

I’ll be back, can’t abide not finishing - - even though I wasn’t the rig in “limp mode”, had my doubts after exhausting most spares that I’d have finished under my own power…. I consider myself a fairly competent wheeler, multiple tough Moab trails and did plenty of YouTube video research, but surprised at the amount of breakage incurred. The upgrade to 35’s not at fault (in my opinion), but was carrying a lot more weight for three days on the trail - - camping and food/beverages plus spares/parts that likely played a role.

Few pics:

Gatekeeper

Kevin assaulting Whale Bones

Jonathon in “Abby Red” - - Phil’s / Kevin’s old Explorer.

Oh yeah, broke a radius arm (Duff) on the way out - - another trail side welding repair; luckily a Good Samaritan stopped and loaned his real welder, as stick welding would have been a real challenge…. No pics, was too busy swearing, but made it out and drove the rig 800 miles back to Tacoma.

Paul