BKennedy's 1994 Explorer

SAS / Re-Wire / Updates in progress;
Bkennedy's SAS and Rebuild Thread

Since I have been a member for over eight years, I thought it was about time I registered my Explorer:

1994 Ford Explorer XLT 4X4
White with tan leather interior
Owned since 1995

Modifications:
The modifications list is mostly up to date as of 04/08/2020. The pictures are older, which show the evolution of my Explorer. There are tons of pictures and modification details in my SAS thread that is linked above.

Front Suspension / Axle;
SAS with 76 F-150 HP Dana 44 cut-down to Early Bronco width.
14" Radflo coilover shocks with Viper 250/300 coil springs and Eibach helper springs.
James Duff radius arms.
BC Broncos, tie rod over steering. Tie rod has been rebuilt with newer, stronger tube.
BC Broncos track / panhard bar.
Custom shock mounts and track bar mounts fabricated by me.
Eaton E-Locker.
Solid diff cover.
5:13 gears.

Rear Suspension / Axle;
Spring Over Axle (SOA).
Custom leaf springs fabricated by North County Spring, Escondido.
Superlift SOA brackets (modified for strength and welded to tubes because they broke).
Rancho 9000XL 11" travel shocks.
Custom shock mounts and cross member.
Detroit locker (used to have a PowerTrax No-Slip but it went boom).
5:13 gears.
Differential guard (forget the brand).

Drive Train;
Stock 4.0 with 1999 Explorer air intake for relocation due to SAS.
GM 700R4 transmission.
B&M Mega floor shifter.
Atlas II, 3.8 transfer case.
Advanced Adapters for transmission and transfer case.
Custom drive shafts with double cardigan joints on both.
Custom transmission cross member with torque arm and skid plates.

Tires / Wheels;
Maxxix Razr's 35X12.5X15 on 15X8.5 ION Alloy wheels.
Custom hub / wheel centric adaptors (4.5X5 to 5.5X5) on rear axle from Bullet Proof.

Interior;
Full internal roll cage (custom bent at first cage building party)
Custom center console with all the accessory switches in one place.
Extra gauges for transmission (PSI/Temp.)
Kenwood CD player
Boss speakers
Cobra CB radio
Kenwood HAM
Few extra switches
Extra lap belt for driver (so I don't have to deal with stock seat belt locking up all the time)

Other Modifications;
Protofab plate front winch bumper (modified to fit from XJ to Explorer)
Custom light hangers
Custom front bumper mounting
Warn 8500 winch
Custom rock sliders welded to frame
Custom rear bumper with swing out tire / gas can rack, CB antenna mount and side protection
Custom roof rack made from 1/2" and 3/4" conduit. Spans most of the roof with 42" curved LED light bar
Two LED light bars; 20" CREE flood, 42" OSRAM curved combo, both have custom made vinyl covers by Zukman
LED rock lights
Second battery in old spare tire area (with custom box)
Puma 12 volt 1HP air compressor and tank mounted with swing down skid plate in old spare tire well next to aux battery
Battery relay type isolator mounted behind grille, 2 manual breakers and a 450 watt mega fuse, all in line
Roadmaster auxillary braking system for "dingy" towing behind RV
18 slot auxiliary fuse panel under hood for all the accessories, including radio, most go to secondary battery
Aluminum water bottle windshield washer reservoir (had to remove stock unit for SAS)
RedHead steering box with fluid plate cooler
Electric cooling pusher fan on trans cooler

Future Modifications/Plans;
Redo the rear bumper tire and gas can mounts DONE

Things I would have done differently;
Tossed the TTB and gone SAS right away (would have saved a lot of money and countless hours trying to make that stock front suspension work)
Had my transmission built by someone other than Bowtie Overdrives
Gone with a Detroit locker in rear the first time

Favorite Modification;
Gears, transmission and transfer case setup.

Pictures;

Rock Crawling (literally, it crawled right up the rock...)

New LED light bars with covers, and roof rack

Pancake Rock Trail (East San Diego County)

Truckhaven;

Corral Canyon;

Custom center console (older version);

New version

Cage work;

Completed cage;

Aux fuse panel and other stuff;

Transfer case / skid plate / cross member;

Old shock mounts

Tow rig (old);

 

[BKennedy]

Very nice! Do you have any better pics or specifics on your rear bumper? I'm planning to have a rear built soon am looking for ideas to steal. Anything you would do differently next time?

Thanks.

The rear bumper is made from a 7X7" square beam that is 1/4" thick. The back half was cut down with a plasma cutter so its much like a regular bumper, just a lot stronger. The swing out carriers are made from 2x2" (I think) square tubing, 3/16" thick, with trailer spindles as the pivots. The sides are tubing added on later.
If I was going to do this again (which I am not) I would make it with thinner material so it was not sooooo heavy. Actually, I would just make it out of tubing so it was lighter, did not take up so much space, and was not a mud catcher.

 

[reapereviltwin]

You have one hell of a nice X there Brian!!!

 

[BKennedy]

You have one hell of a nice X there Brian!!!

Thanks. The only modifications I have done to it in the past year are;
The Throttle Cable Modification, and blown a front shock.

 

[DeRocha]

Your 1st Gen is Very sweet indeed..

 

[whitetrash96]

Okay, I have a couple more bumper questions. Who manufactured your front bumper? Its from a cherokee right? How does it fit width wise? Thanks.

 

[BKennedy]

Okay, I have a couple more bumper questions. Who manufactured your front bumper? Its from a cherokee right? How does it fit width wise? Thanks.

Its from Protofab in Arizona. I found it on a web search. It fits fine. If you want a bumper from an XJ to fit an Explorer, you have to cut the frame of the Explorer off at the first body mount, then weld a cross plate for new bumper tabs.

 

[BKennedy]

I finally did some upgrades to the Explorer!
New leaf springs and tires;

This was prompted by having bald tires, and a broken leaf on the right side. Made a set of leafs from two stock leaf packs. More information here;
http://www.explorerforum.com/forums/showthread.php?p=3093948&posted=1#post3093948

 

[Rick]

Looks like a nice tread pattern on the tires. We'll get to try them out real soon

 

[BKennedy]

Looks like a nice tread pattern on the tires. We'll get to try them out real soon

It has been a long time since I sprung for new tires. I backed up on that rock in 2WD so fast I almost went over it. The BFG's dropped in price and Discount Tire matched Tire Rack's internet price. Can't beat that.

 

[BKennedy]

New leaf springs;
Modification thread is here; http://www.explorerforum.com/forums/showthread.php?t=372601

 

[Gopher]

Brian!

How's it going? Who's doing all your welding? I need to look at getting my steering and my front spring/shock mounts handled. By handled, I mean my springs are still SUPER bowed!!!!

and yes i'm still alive, just my truck is a sitting piece that needs work.

 

[BKennedy]

I am doing my own welding. I have a 110v Lincoln welder that I do small stuff, and tacking up with, and have access to a Hobart commercial MIG welder that a friend of mine has. Don't know the model, but its big and heavy, and lays down a index finger sized bead in nothing flat. He bought that, and a plasma off a fab shop that went under.
Nice to hear you are still alive; what's it been, five years??

 

[Gopher]

Yes Sir! Now married, looking for homes, and studying for my Professional Engineer license in California.

The explorer is my weekend driver that I've just about had it with the front-end and want to look at getting it fixed.

I'm back to checking on the board so I won't miss out on upcoming trips.

Maybe I'll see ya in October when I take my exam at the Del Mar Fairgrounds!

 

[BKennedy]

SAS in progress...............
http://www.explorerforum.com/forums/showthread.php?t=387037