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<meta name="Author" content="Copyright 1999 Rick Horwitz All Rights Reserved">
<title>Paul Sabins's 1991 Explorer Sport</title>
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<td VALIGN=TOP><b><font face="Arial,Helvetica">Editor</font></b>
<br><b><a href="mailto:explorer@4x4central.com">Rick Horwitz</a></b>
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<center><img SRC="otbt.jpg" height=52 width=330><br>
<font color="#003399"><font size=+2 face="Arial,Helvetica">Paul Sabin's&nbsp;</font>
<br><font size=+2>1991 Ford Explorer Sport</font></font><table BORDER=0 CELLPADDING=5 >
<tr>
<td>
<p align="center"><a href="archpaulsonledge.jpg"><img SRC="archpaulsonledgesml.jpg" BORDER=1 height=179 width=265></a>
&nbsp;<font size=-2><br>
Perched atop Arch Canyon</font></p>
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</table></center>
<center><table BORDER CELLPADDING=5 WIDTH="70%" BGCOLOR="#FFFFFF" >
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<td><font face="Arial,Helvetica"><font size=-1>I bought my 91’ Sport in
the spring of 1993. I kept the Sport bone stock for the first few years,
primarily because I was not yet afflicted with the "build-up bug". Off
roading was limited to the beaches of North Carolina and local ORV trails.
The Sport performed well, but would be a stellar performer with a few upgrades.</font></font>
<p><font face="Arial,Helvetica"><font size=-1>The first modification was
the installation of the Borla Headers and Cat-Back Exhaust system, installed
in 1995. The Sport was towing our other vehicle from North Carolina to
our new residence in Washington State and felt it was the ideal excuse
to add some bolt on performance. At this time I also added the K&amp;N
filter, and swapped out the original rubber with 30x9.50x15 Firestone ATX
tires. The tires fit fine and the stock 3.55 gearing was adequate to compensate
for the size difference.&nbsp;</font></font>
<p><font face="Arial,Helvetica"><font size=-1>Although the truck was still
largely stock, we still enjoyed taking it to the area beaches and limited
4x4 trips throughout Washington State. The only modification was the Smittybuilt
dual tube bumper (after backing into a telephone pole). It was not until
this past year that the build-up began in earnest.</font></font>
<p><font face="Arial,Helvetica"><font size=-1>In September of 1998 I had
the Rancho 2&frac12;" Lift Kit installed. My rationale on the 2&frac12;"
kit was based on the thought that I wouldn’t go bigger than 31" tires and
didn’t want to have to lengthen brake lines, install heavy duty brakes,
or upgrade to lower gearing. I chose AR 767 steel 15x8 rims with 4" of
backspacing. Although I could have kept the original rims, the stock 5&frac14;"
backspacing on the 7" rims caused the front tires to rub the Rancho extended
radius arms short of full steer.</font></font>
<br>&nbsp;
<center><table BORDER=0 CELLPADDING=5 >
<tr>
<td><a href="paulschassis.jpg"><img SRC="paulschassissml.jpg" BORDER=1 height=153 width=230></a></td>
<td><a href="paulsradius.jpg"><img SRC="paulsradiussml.jpg" BORDER=1 height=153 width=230></a></td>
</tr>
</table></center>
<p><font face="Arial,Helvetica"><font size=-1>For tires I went with the
31x10.50x15 Firestone RMT (Radial Mud Terrain). They are similar to the
BFG Mud Terrain, but the tread pattern is not quite as aggressive. The
on-highway ride is fine. To date I have been impressed with their performance
in mud, slick rock, loose gravel, and sand. The 4" backspacing gave the
Sport a wider stance, but at the cost of exposing the front tires outside
of the fender well. The solution was Bushwhacker’s Extend-a-Fenders, which
fit perfectly.</font></font>
<p><font face="Arial,Helvetica"><font size=-1>After the switch to the 31s
I added the Jet Performance Chip. Although the gains did not seem significant,
any small bit to increase horsepower is welcome. At this time I ordered
the James Duff Pre-Runner style front bumper. I had the rear tubular style
and wanted to mirror the same style up front. After about three years the
Smittybuilt was showing it’s age, so before mounting the Duff bumper I
had both front and rear bumpers sprayed with Line-X, a commercial truck
bed lining. This gives the bumpers a textured rubberized coating that to
date has stood up well to off road driving conditions. The Duff bumper
had light tabs so I mounted Hella 500 fog lights up front. Both bumpers
look great, and the new front bumper allowed me to mount GM tow hooks to
the frame. I like the GM hooks because they are flat, keeping a yank strap
from sliding off as well as being a great jacking platform for the Hi-Lift.
I also created a drop bracket from squared steel tubing to mount GM tow
hooks to the rear of the vehicle, which again makes a great jacking platform.&nbsp;</font></font>
<br>&nbsp;
<center><table BORDER=0 CELLPADDING=5 >
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<td><a href="paultowhook.jpg"><img SRC="paultowhooksml.jpg" BORDER=1 height=153 width=230></a></td>
</tr>
</table></center>
<p><font face="Arial,Helvetica"><font size=-1>Next was traction control
and gearing. By now I really had the build-up bug and wanted to get great
traction without sacrificing on-highway performance. I looked at all conceivable
options: Limited Slips,&nbsp;&nbsp; E-Z Locker, Detroit, "Clutchless" and
of course the Air Locker from ARB. Since my truck is a daily driver, lockers
front and rear would probably be too hard on the drive train. I could not
find a limited slip for the front reverse cut Dana 35- - but I’m sure they
are out there somewhere. The final outcome was the ARBs. Most expensive
of the bunch, but the first climb I would have not made with limited slips
would have made wish I’d dropped the extra money for the ARBs. With traction
improvement I also went to lower gearing, settling for 4.10s. Although
my initial intent was not to swap gears, I found the 3.55s lackluster with
the 31s. Additionally, I plan to go to at least 32s, so I figured the deeper
gears would be better suited for future upgrades.&nbsp;</font></font>
<br>&nbsp;
<center><table BORDER=0 CELLPADDING=5 >
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<td><a href="paulsclmb.jpg"><img SRC="paulsclmbsml.jpg" BORDER=1 height=153 width=230></a></td>
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</table></center>
<p><font face="Arial,Helvetica"><font size=-1>I’ve recently added a Con-Ferr
roof rack, Warn Lock Out Hubs, and the KKM filter element.</font></font>
<p><font face="Arial,Helvetica"><font size=-1>Future upgrades include armor
for the front and rear differentials, and rear shock mount skid plates.
Additionally, I’m planning to fabricate a storage system for the rear cargo
area.</font></font>
<p><font face="Arial,Helvetica"><font size=-1>Only regret (or "If I had
to do it all over again") I would have probably gone with a 4" lift kit
in lieu of the 2&frac12;" kit. I have a very capable off-road vehicle,
it would be more so with 33" tires.&nbsp;</font></font><br>
<hr SIZE=1 WIDTH="40%">
<p><b><font face="Arial,Helvetica"><font size=-1>Specifications</font></font></b>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Engine&nbsp;</b>
- 4.0 L V-6</font></font>
<br><font face="Arial,Helvetica"><font size=-1>&nbsp;&nbsp;&nbsp;&nbsp;
KKM Filter</font></font>
<br><font face="Arial,Helvetica"><font size=-1>&nbsp;&nbsp;&nbsp;&nbsp;
Jet Power Chip</font></font>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Suspension </b>-
Rancho 2 &frac12;" Suspension Lift Kit</font></font>
<br><font face="Arial,Helvetica"><font size=-1>&nbsp;&nbsp;&nbsp;&nbsp;
Rancho RS 9000 Adjustable Shocks&nbsp;</font></font>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Transfer Case</b>
- Borg-Warner 1354, Electronic</font></font>
<br><font face="Arial,Helvetica"><font size=-1>&nbsp;&nbsp;&nbsp;&nbsp;
Warn Lock Out Hubs</font></font>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Axles</b>&nbsp;
- Front: Dana 35 reverse cut, 31 spline shafts</font></font>
<br><font face="Arial,Helvetica"><font size=-1>&nbsp;&nbsp;&nbsp;&nbsp;
Rear: Ford 8.8", 31 spline shafts</font></font>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Exhaust</b>&nbsp;
- Borla Headers</font></font>
<br><font face="Arial,Helvetica"><font size=-1>&nbsp;&nbsp;&nbsp;&nbsp;
Borla Cat-Back Exhaust</font></font>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Gearing</b>&nbsp;
- U.S. Gear - 4.10 Gears</font></font>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Differentials</b>&nbsp;
- ARB Air Lockers</font></font>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Tires</b>&nbsp;
- 31x10.50x15 Firestone RMT</font></font>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Wheels</b>&nbsp;
- American Racing 767 Steel 15x8</font></font>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Bumpers</b> - Front:
James Duff Pre-Runner</font></font>
<br><font face="Arial,Helvetica"><font size=-1>&nbsp;&nbsp;&nbsp;&nbsp;
Rear: Smittybuilt</font></font>
<br><font face="Arial,Helvetica"><font size=-1>&nbsp;&nbsp;&nbsp;&nbsp;
Both sprayed with Line-X textured bed liner</font></font>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Lighting</b>&nbsp;
- Hella 500 6" Fog Lights</font></font>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Electronics</b>
- Radio Shack CB&nbsp;</font></font>
<p><font face="Arial,Helvetica"><font size=-1>&nbsp; <b>Miscellaneous</b>
- Con-Ferr Roof Rack</font></font>
<br><font face="Arial,Helvetica"><font size=-1>&nbsp;&nbsp;&nbsp;&nbsp;
Bushwhacker Extend-a-Fender Flares</font></font>
<br><font face="Arial,Helvetica"><font size=-1>&nbsp;&nbsp;&nbsp;&nbsp;
GM Tow Hooks front and rear&nbsp;</font></font>
<p align="center"><b>Contact Paul:</b><br>
<a href="mailto:ptsabin@lvnworth.com"><b>ptsabin@lvnworth.com</b></a></td>
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