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Brian1's Twin Trail Build (Lift, Gears, TTB Mods, Bumpers, Sliders, Cage & More!)

Brian1's Twin Trail Build

1991 Ford Explorer 4-Door XL 5-Speed Manual 4x4

Project Background and Goals:

I bought this Explorer at a Police auction in August of 2015. I really didn't know what I was going to do with it when I bought it but I couldn't pass up the great deal I got. I stored it away for a bit while deciding to part it out, build it up or just flip it. In the end I decided to build it into a cheap trail truck and use it to R&D some new ideas I had on how to build an Explorer and develop some new parts.

The goal of the build was to do it cheaply while keeping it low, lightweight, and simple. Another goal was to completely transform the Explorer into a trail machine and debut it at the 20th anniversary forum run in Moab (May 2016) while keeping the entire build a secret.

The build has already been completed and made its successful debut in Moab. I will be adding to this thread as time permits of what I did.

Table of Contents - Modifications

to be filled in as the thread progresses for quick access

1" Body Lift
Rear 8.8 Swap and Build
Rear F150 Hybrid Leaf Springs
Front Daystar 2" Coil Spacer & F250 Shock Tower Conversion
Corbeau Seats Pt1
Corbeau Seats Pt2
Rear Shock Bar Pin Eliminators
Dana 35 TTB Beam Boxing
Hybrid Dana 35 Beams with Dana 44 Outer Conversion
Extended Radius Arms
Dana 35 Diff Build with LockRight Locker
Power Steering Cooler
Cutting the Rocker Panels Off
Rear Bumper Build
Front Fender Cutting
Rock Sliders Pt1
Rock sliders Pt2
Front Winch Bumper Build
Extended Breathers and Fuel Pump Access Panel
Rear Fender Cutting
Cage Building
Fabricated Door Panels/Skins


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BKennedy

Elite Loser
Staff member
Moderator
Elite Explorer
Joined
November 29, 2000
Messages
7,975
Reaction score
1,418
Location
USA
City, State
San Diego, PRofK
Year, Model & Trim Level
1994 XLT
Did you find that Element 50 extinguisher for any less than $79.95? Seeing them for the first time here and now I need one for each car. Also link to the mounts you used?
 




Brian1

Elite Explorer
Joined
February 2, 2000
Messages
5,273
Reaction score
369
City, State
Albuquerque, NM
Year, Model & Trim Level
1991 XLT
Callsign
KG5BAQ
Did you find that Element 50 extinguisher for any less than $79.95? Seeing them for the first time here and now I need one for each car. Also link to the mounts you used?

Yes, but it was a Black Friday sale at Northridge4x4. I got 3 at around $65-70ea IIRC. Before that I even looked into buying a case and going in with a few friends but you dont save too much. Element has a pretty tight lock on lowest advertised MSRP it seems like.

Each one comes with a single plastic clip/mount which works fine, I just wanted a little something more robust. www.mcmaster.com part # 1723A24 is a pack of 10.
 




Brian1

Elite Explorer
Joined
February 2, 2000
Messages
5,273
Reaction score
369
City, State
Albuquerque, NM
Year, Model & Trim Level
1991 XLT
Callsign
KG5BAQ
My stock 5-speed shift knob split out the bottom and became loose so I ordered a new replacement one on ebay for cheap, equivalent to Ford Part # 5L5Z-7213-AA. It weighs more than the stock knob and has a little different feel but its pretty nice for the price. I had to smack it on with a rubber mallet to get it to seat on the splined shifter rod.

New on Left-

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Paul

Elite Explorer
Joined
August 18, 1999
Messages
1,127
Reaction score
250
City, State
Grit City, Washington
Year, Model & Trim Level
'94 “Sport”
Looks like the stock shifter knob on my 2011 Ranger - - a decent replacement, but quite the downgrade in materials and appearance from the 90's. . .

Paul
 




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