Paul's '91 Sport

“Three ashtrays, two doors, one cup holder, and zero Air Bags”

As it sits today. . . (December 2023)

As it sat last year. . . (2022)

Edit: From here on down was the write-up I did for my first Explorer before it was totaled in a commuting accident in March 2017. The write-up for the new (to me) Explorer that was acquired in May 2020 starts on page 2, post #31.

I am the second owner of this vehicle, purchasing it in April 1993. It has been a daily driver, crisscrossed the States multiple times, sat for a few years in storage, and now is dedicated to four-wheeling trips, camping excursions, and hauling the motorcycle to various “track days”. It is not a hard-core rig, but is set up well for the types of four-wheeling I enjoy, and has certainly seen its fair share of difficult trails. It has a number of modifications, with more planned for the future, but is by no means “Done”.

As it used to sit: (2016)

Here is the run-down of the modifications and when they were installed (or re-worked). . .
- Borla Headers and Cat-Back Exhaust (1995)
- James Duff Pre-Runner Front Bumper (1998)
- Bush Whacker Extend-A-Fender Flares (1998/2016)
- ARB Air Lockers, front and rear (1999/2008/2015)
- 4.10 Gears (1999)
- “SupeRancho” Hybrid Lift, approximately 4” of lift, with SOA (1999)
- 33”x 12.50 Tires (currently Toyo Mud Terrains)
- Con Ferr Roof Rack (1999)
- SuperLift SuperRunner Steering (2000)
- Ramsey REP 8000 winch in Duff Bumper (2002), Warn Synthetic Line (2016)
- Rock Sliders (2002)
- Atlas II Transfer Case (2005)
- ViAir On-Board Air Compressor (2009/2014)
- Modified ¾ Doors (2009)
- Early Bronco fabbed Rear Bumper, “extra modded” to fit the Explorer (2009)
- Rear License Plate Frenched (2009)
- Outback Solutions (ARB) Drawers with fabbed pull-out shelves (2012)
- Corbeau Heated Seats (2013)
- Internal Roll Cage (2013)
- Shelf/Box/Switches (2013-2015)
- Lights – Raptor/Fog/Roof Rack/Rear/Squatch/Interior Hatch/Hood (2013-2016)
- Dual Battery installation (2014)

I'll document most of the projects in subsequent posts with pictures and links to various threads. . .

Paul
'91 Sport





Edit: End of the road in April 2020. . . Read on for the wreck and renovation/restoration/gear swap to new 'Sport'. . .

 

[Paul]

Seating Upgrade (Cont.):

Since everything is torn apart, thought I'd give the frame rails a fresh coat of paint:

. . . and threw some grease on the rails and some oil on the springs.

Switch location for the heated seats was a no-brainer - - just forward of the OEM lumbar and bolster switches:

Finished seat, ready to go back in:

Going to spray them down with upholstery/carpet cleaner tomorrow before the install, and although the wiring for the heated panels is complete, still need to pre-run the other three wires for the as-yet-unused fuses in the fuse block in the center console.

Paul

 

[Paul]

Dash Light Upgrade:

Knew the dash "idiot" lights were not all working, also a burnt bulb on one of the turn signal indicators, and half of the backlight bulbs for the dash were inop, so added an LED dash light upgrade to the "Drivability" List.

Here's the dash:

Swapped out the old bulbs (lower) with LED replacements (upper), but decided to keep regular bulbs for the turn signal indicators in case there was a resistance issue with the LEDs (turn signal indicator bulbs also replaced with new, just not LED).

A whole lot of effort to replace a dozen or so light bulbs. . .

. . . but worth in the end.

Noticed that the P.O.'s mechanic had been in the dash at one time - - a wad of electrical tape in the "ABS" light socket . . . , but worth noting to anyone considering digging into their dash for an LED upgrade - - the sockets for the bulb have to be inserted correctly. It's a simple quarter-turn twist, but if you line up the bulb holder on the 180, the bulb won't illuminate. Not certain the P.O. or last mechanic was aware of that, as half the bulbs were still "good" just inserted 180 degrees and not functioning. Since there is always risk when flexing 26 year old plastic trim pieces, don't want to pull the dash apart again, so used the new LEDs (except turn signals) no matter the condition of the older bulbs.

Paul

 

[410Fortune]

I do the same with the ABS light...you cannot remove the bulb on the 95+ trucks or you will get a warning chime, so I use liquid electrical tape to paint the back side of the abs indicator and then a wad of electrical tape like you said to block the rest of the light.
Looks awesome!!

 

[Paul]

you cannot remove the bulb on the 95+ trucks or you will get a warning chime

Another reason to love the 1st Gens! ! !

Stuff for the next project arrived today. . .

(Visor shelf) . . .

Paul

 

[gmanpaint]

Visor shelf.... For switches?

 

[Paul]

Yep. . . kind of a theme. . .

('91 Sport above, '11 Ranger below)

Just seems to be the best place to put them, at least for me. . . In the '91 Sport, started on the door panel (near window/door lock switches), that wasn't good, then knee panel, then under ashtray, etc., etc. The final option was visor shelf area (actually tied to cage, but you get the idea).

Visor also good for quick "out of sight" storage for pilferable items when I stop someplace - - phone, sunglasses, spare mags, etc. With this rig, really don't want to carve up the plastics, so the visor shelf "does no harm" to the interior. . .

Only drawback may be the lower sightlines for the driver - - not much of an issue for me. . .

Paul

 

[gmanpaint]

Nice. Please give a how too, with pictures along the way.

I was searching today for a place to put a few rocker switches, and have been searching for a surface mount box to use. Thought of purchasing an A pillar switch mount made for jeeps, and modifying it to fit. That doesn't appeal to me, but was running out of options.

Your idea might work, or might not. 2nd gen has the overhead console between the visors to deal with.

 

[Paul]

Please give a how too, with pictures along the way. Your idea might work, or might not. 2nd gen has the overhead console between the visors to deal with.

Fairly simple install, but of course nothing is easy - - can't find a shelf for any RBVs (looked for awhile for the Ranger before stealing the black one out of the Sport. The one pictured above is for a similarly aged F-150, so I'll have to lop off about 4" per end, lengthen the lighting wires to the visors, etc. etc. etc. Will post some pics as I get to it this weekend.

Might not be an viable option if you have the overhead console in the "Black Hole", but once I get it installed shoot me a PM and I'll take some specific measurements and photos if you think that will help.

Paul

 

[gmanpaint]

Might not be an viable option if you have the overhead console in the "Black Hole", but once I get it installed shoot me a PM and I'll take some specific measurements and photos if you think that will help.

Paul

Thanks Paul! I do appreciate that.

The BH does indeed have the upper console. I took one apart at the salvage yard last weekend to see if it would hold a couple rocker switches (ARB), but it won't. I have literately ran out of places to add rocker switches! lol

 

[410Fortune]

rocker switches are so 1999

Raxiom Jeep Wrangler Bluetooth Light Switch & Accessory Controller J107752

FREE SHIPPING! Wireless Saves Time and Effort. Save considerable time and stress when you want to install electronic accessories in your Jeep Wrangler with the

www.extremeterrain.com

they even have bluetooth enabled relays these days...control all your lights, amps, accessories with your phone!!

 

[Paul]

they even have bluetooth enabled relays these days...control all your lights, amps, accessories with your phone!!

You damn kids with your wireless controls and Depeche Mode rock & roll music! ! ! Now get off my lawn! ! ! Ha!

Visor Shelf Install:
As mentioned, the only shelf I could find that I figured would fit (or be made to fit) came from a 1995-96 F150, but it did come in tan to match the interior. Simple removal of visors and stems, then on to the modifications. . .

Three screws for the visor mount, bracket has five - - and of course none of them match up.

So into "template mode" to get the right fit:

Mount the brackets and check distance to trim shelf.

(blue painters tape protects the shelf from the jig saw)

Fine tuning with the Dremel:

Test fit:

More to follow, just didn't get it all crammed in this weekend. . .

Paul

 

[Paul]

Visor Shelf Install (Cont.):

Too many projects lately, but got this project where it needs to be for now. . . Since I had to trim off the "ends" that had the pre-fabricated spots for the visors, had to make a few openings. . . The visor loses it's "cant", but still sits flush and folds down to block the sun.

Next was extending the wiring for the light in the mirror section - - nothing special, but takes time since the visors are 3-4" lower than OEM.

Proof of "light":

The "center" tab mounts near the rear-view mirror are mounted to the shelf similar to OEM to secure the ends of the visors.

And test fit for the switch panel harvested from the old Sport.

(Full Disclosure: This photo taken before the visors mounted)

Still need to find some larger tan colored fastener push-pin clips to cover the holes in the headliner where the center tabs for the visor mounted.

Paul

 

[Paul]

Back to work on the rig . . .

Received a "Christmas in July" package last week from Brian1 with parts for the build, so started some deconstruction - - so off with the plastic cladding. . .

Wheel lip trim also removed:

Saved/salvaged the "unobtanium" Bushwhacker Extend-a-Fender flares from the 'Sport - - will need to be reconstructed as the damage from the wreck added some more scars to them . . . in time.

Paul

 

[Paul]

Finishing touch on the Visor Shelf project:

And eye candy from Brian1:

Paul

 

[Paul]

Some more test fitting . . .

(had to rework those top corner edges - - not "clean" enough).

Paul

 

[Paul]

Fairly dormant on this thread - - been busy with other projects (FXR) and work stuff. . .

Here's some progress:

That right there is "Medium Seafoam Metallic". . . as matched to the OEM paint code on the current rig, and yep, looks a lot like the "Crystal Meth Blue" I had on the '91. . .

Weird sequencing, but need to Monsta-line some parts and lowers of the rig, so paint came now. . . before the wrenching. . . It'll be fine. . .

Paul

 

[Rick]

Some more test fitting . . .
View attachment 319885

(had to rework those top corner edges - - not "clean" enough).

Paul

Are you having flashbacks as you're doing this? It's like going back in time!

 

[Paul]

Are you having flashbacks as you're doing this? It's like going back in time!

Well, it is "Throwback Thursday" . . .

2009:

(Funny thing - - I picked these doors off a Navajo - - painted Medium Seafoam Metallic!)

2010:

(This frenched plate holder I fabricated from a Chevy Astro piece - - the new one is steel and I added angle iron around it for easier mounting to the hatch - - also moved the new one closer to center).

So yep, going back in time. . .

Paul

 

[Suicide77]

Paul,

Sorry to hear about the BIII - it is a ride that I consistently tell friends about when Explorers work their way into a conversation. Glad I got to see it wheel down in moab, but also looking forward to following a build thread like the good old days! Good luck with the new rig - happy to see some sweet progress already

 

[Paul]

Sorry to hear about the BIII - it is a ride that I consistently tell friends about when Explorers work their way into a conversation. . . Good luck with the new rig - happy to see some sweet progress already

Anthony, thanks for the comments - - glad you're still here, have checked in on the CPT America and Mad Max threads, good to see you still plugging away. . . Taking my time with this project (maybe too much!), but the goal is to get it done with plenty of shake-down time before Moab next May.

Paul