Darkfox
"Punching it" results in the engine attempting to change from lower fuel flow to higher fuel flow, rpms, etc. and this "step change" can cause some unburned gasoline vapors to flow out the exhaust, overwhelm the cat, and result in this "sulfur smell". I noticed in looking at the exhaust flow diagrams for some older vehicles that there were actually bypass arrangements for these high hydrocarbon exhaust gases (resulting from acceleration or "punching it") to bypass the cats to prevent the cats from burning up (i.e. as the emission control system has the warranty, car manufacturers' were designing these by-pass systems to avoid the tatalytic converter replacement costs - I think EPA caught them and the bypasses are now not allowed). I would guess that your driving without "punching it" will avoid the sulfur smell - and by the way, there must be something haywire if you can smell this inside your Explorer (like a leaking exhaust system). By the way, I am not implying you should avoid "punching it", I am just trying to explain what is going on. As others have commented, the O2 sensors, air/fuel ratio computer, or something is probably not operating properly. And there is always that issue of dirty fuel injectors which can screw up the fuel flow to certain cylinders, O2 sensor output, and the computer trys to adjust but the fuel injectors do not cooperate, engine then does not operate properly.
For my Ford, I surely noticed the difference in engine performance (especially at high rpms) just putting in a new air filter and cutting the holes in the airbox. Installing the KKM should make an even better improvement (yes, I have a KKM).
Good luck. Keep us posted on how it all works out.
Mike with 91 4x4 Explorer in a wet rainy Seattle.