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Paul's '91 Sport

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

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 sits today. . .
Front Oblique (P).jpg
Rear End.jpg


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'. . .
Fork (APR 20).jpeg
 
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Paul

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City, State
Grit City, Washington
Year, Model & Trim Level
'94 “Sport”
Wiring Day . . .
Bumper Lights.3 (JAN 21).jpg


Every time I think I've got it all figured out, feels like I'm starting from scratch. . .
Switch Panel (JAN 21).jpg


Luckily I've got a cover to hide all that spaghetti wiring. . .
Panel Cover (JAN 21).jpg


In the end. . .
Lights On (JAN 21).jpg


And. . .
Switch Panel (JAN 21).jpg


Paul
 
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Paul

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'94 “Sport”
Got a chance to field test the repair of the rear ARB airline from a few weeks ago at Kevin's shop as well as check any clearance issues with the rear bumper with a solo "snow run" up to Haller Pass for a little anniversary snowshoeing with the Mrs.
Haller.4 (JAN 21).jpg

No issues with the bumper or swing-away tire carrier, but didn't really expect any. . .

Less snow than I expected at the pass. . .
Haller.3 (JAN 21).jpg

Rear ARB line worked like a champ, so glad that's off the list.


So we tromped around a bit - - surprised that there were not many others out - - saw a handful of Jeeps and few Toyotas, but not much else.


Old guy and the better half . . .
Haller Anniversary.2 (JAN 21).jpg


Now need to plan out the front bumper/winch options as it'll take a while to get that sorted and Moab is coming - - like in a 100 days ! ! !

Paul
 
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Paul

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Latest performance mod:
2A (JAN 21).jpg


Unfortunately the Left Coast will lurch farther left with the race to socialism, so always gotta fight the "woke" crowd whenever possible . . .

Paul
 
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Kirby N.

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I dig the build. Same color as my old Navajo- brings some nastolgia for me! I made mine a Ford too because back then Navajo parts were hard to find and expensive. So when I smashed the grill it was tough to get parts.
It looks great Paul. I have appreciated building my ranger as a second go around too. Applying everything you learned the first time and you sure come out with a good product in less time.
 
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BKennedy

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Wiring Day . . .


Every time I think I've got it all figured out, feels like I'm starting from scratch. . .
View attachment 326897
Your wiring looks neat, just a lot of it. I like the ceiling panel, I used to have a back up camera monitor on the cross member of my roll cage, but went through a bunch of cameras because they can't handle off-road. I went back to my old back up until it stops moving method (only in the dirt, not parking lots).

Have you thought about using a small fuse block like these?


I bought some of the 4 fuse blocks and have one in the rear of the Explorer in the jack access, and one in the RV at the batteries. They are very convenient and it gets rid of all those in-line fuse holders. You also don't need to fuse all of those AC plugs separately. One fuse would be able to handle the light load they are going to carry. You could get away with extending the AC plug wires in the ashtray that is already on a fuse. I have a bunch of those AC plugs and have the plugs in the front on one fused line, and the plugs in the back on another. They all run off the auxiliary battery. I also have a 18 fuse block under the hood that came out of a Kia with most of my accessories tied into that. If I was doing it over again, I would purchase a aftermarket waterproof fuse block for under the hood. I have it covered with a piece of soft rubber sheeting.
 
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Paul

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'94 “Sport”
I dig the build. Same color as my old Navajo- brings some nastolgia for me! I made mine a Ford too because back then Navajo parts were hard to find and expensive. So when I smashed the grill it was tough to get parts.
It looks great Paul. I have appreciated building my ranger as a second go around too. Applying everything you learned the first time and you sure come out with a good product in less time.
Thanks Kirby! Following along with your Ranger build, looking awesome - - apologies for not having a spare Atlas II for your build, but my old one found a good home. . . Always thought your "Sport" was light blue like my old one, swear sometimes it looks the same, but it's a seafoam green metallic. It's been a fun build, and good working with Kevin; this rig certainly came together quickly, but had a few to take the best parts off of. . .
Your wiring looks neat, just a lot of it. I like the ceiling panel, I used to have a back up camera monitor on the cross member of my roll cage, but went through a bunch of cameras because they can't handle off-road. I went back to my old back up until it stops moving method (only in the dirt, not parking lots).

Have you thought about using a small fuse block like these?


I bought some of the 4 fuse blocks and have one in the rear of the Explorer in the jack access, and one in the RV at the batteries. They are very convenient and it gets rid of all those in-line fuse holders. You also don't need to fuse all of those AC plugs separately. One fuse would be able to handle the light load they are going to carry. You could get away with extending the AC plug wires in the ashtray that is already on a fuse. I have a bunch of those AC plugs and have the plugs in the front on one fused line, and the plugs in the back on another. They all run off the auxiliary battery. I also have a 18 fuse block under the hood that came out of a Kia with most of my accessories tied into that. If I was doing it over again, I would purchase a aftermarket waterproof fuse block for under the hood. I have it covered with a piece of soft rubber sheeting.
Thanks Brian! Those in-line fuses were built into the switch-panel: 1 x 12v socket, 1 x cigarette lighter (really?), 1 x voltmeter, and 1 x with two USB plugs. Agree it's overkill, but since those four in-lines were already mounted I opted just to leave them as is. The greatest bulk of wiring is for the ARB Compressor and front and rear lockers, but really wanted to mount them overhead instead of cutting up the dash or mounting them under the dash (hard to reach with the stick shift).

Do have the Blue Seas fuse blocks (another bad habit is wooden boats) in both this rig and the Ranger.

Wiring Fuse  Block (MAY 20).jpg


With the recent add-ons, this one is almost full, so when I get around to mounting the drawer system in the cargo area, will add another back there...

Appreciate the comments - - front Duff bumper ordered and with luck will get here in time to do the required fab work for the "covert" winch install before the Moab trip. . .

Paul
 
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BKennedy

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I have a four fuse block mounted in the rear inside the panel in front of the jack storage
20200501_154842.jpg


I also have the twin stick awesomeness that is a Atlas II. Made a center console with all of my accessory switches in one place.
20190905_171317.jpg
 
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Paul

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Sweet looking console and shifter. Realize you've upgraded to the 700R4, but wish all the 1st Gens had console mounted automatics. . . . Just looks better than the column mount, IMO.
 
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BKennedy

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Its also way better in the dirt for quick shifts, much easier to grab the shifter in the console than one on the column.
 
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410Fortune

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an atlas would like so complete my BII build
Keep up the good work dudes! I enjoy watching
 
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Kirby N.

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My ranger too. And a new engine. Maybe a new tranny depending on engine. And a new tailgate. And a cage. And sliders and more tube on my bumpers. And...

Never complete.
 
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Paul

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Mr. Duff came through ! !
Bumper Unfinished (MAR 20).jpg


Some mods this weekend to fabricate space for the "hidden" winch . . . another hold-over from the old Sport.

Paul
 
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Paul

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"If you wait to the last minute . . . , it only takes a minute. . ."

A whole bunch of "must-do's" before Moab (coming up quick), some more important than others, but all essential. Here's another transfer from the old rig:
Drawer Frame (APR 21).jpg

Frame in. . .

Color change for the deck lid and accessories. . .
Drawers In (APR 21).jpg

The "slides" that went on the deck lid that the ARB fridge pulls out on will wait until post-Moab. . .

More to follow,

Paul
 
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Kirby N.

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Sweet setup. Super clean. What drawers are those?
 
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Paul

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'94 “Sport”
Sure are a lot fancier than my tupperware drawers.
10% of the cost, 90% of the efficiency. . . Well done.

Finally got the front end buttoned up (almost, still need to wire the fog lights), but coming together . . .
Bumper (APR 21).jpg


Closer detail of the front bumper / winch / skid plate.
Winch (APR 21).jpg


That's a non-winch Duff bumper, but with a Ramsey REP 8000 winch snugged in between the frame rails - - another carry-over from the old Sport. . .

Paul
 
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