Pelton Party Wagon Gen 1 Explorer

[59sled]

So my younger 23 year old kid wanted a 4 seater prerunner project.
Probably wont be much of a build thread as most of the work is done already. But we all know how these projects snowball.

He saw that @Nick619nc had to explorers for sale on Marketplace
One was kind of built but was rolled onto the roof and he also had a non running donor explorer for a body swap.
So we did the 3 hour drive down to San Diego to bring them back home.


The rolled one has a
Front
Solo Motorsports stage 4 kit on it. With cut and turned beams.
Solo shock hoop brace kit.
King 2.5x12 coil overs
King bump stops.

Rear
Cookcraft rear shock mount kit.
Fox 3.0x12 triple bypass shocks
Deaver G50E springs
Solo shackles

Almost new 35" Tensor tires and AR23 wheels.
New clutch and flywheel
new steering box
Baja Designs dome lights
Baja Designs rear chase light
3 Baja designs in the grille
Auxbeam 8 gang switch panel.

Pics of the goodies on the rolled one.

 

[59sled]

Only a 1/4 mile away from leaving Nicks house with both Explorers, we get flagged by someone that our trailer tire is smoking and rubbing the fender. Pulled into a parking lot and realized we lost a shackle on the way to his house. Didn't notice it when we loaded that one trailer.




Tractor supply company 9 miles away for the win.

 

[59sled]

Now how do we get a non running one parked in the up hill front yard next to the driveway with only 3 people.
You back it up to the porch where its flat with the hopes to push it downhill into its spot.
But don't forget to jack up the trailer tongue and truck to make it level as possible.


Everything looks like it will work, Lets push it off and proceed to run it into the porch swing and the front house pillar.
Just miss the marked by a half inch. Unfortunately we got a little damage to the passenger taillight. And of course that's the one taillight we actually needed. Oops.

 

[59sled]

Some of the body damage from the rolled one.

 

[59sled]

Sorry neighbors about the sudden drop in your property values.

 

[59sled]

We've never done anything like this before, but how hard can it be. Just unbolt somethings. Haha.
But we realize its a little more involved than we first thought.
One is the wiring. We were hoping not to have to transfer wiring harnesses. But the rolled 92 has a electric transfer case and the 1994 donor is a 2wd. Also we noticed upon pulling out both interiors that the 92 rolled one has a few extra relays around the rear water reservoir. and a computer box on the drivers rear quarter right by the washer tank. You can kind of see it in the picture below, One has the box and the other doesn't. So looks like we need to transfer the rolled wiring harness to the new donor body. Just a little more work. But shouldn't be that hard if you take your time and label and take pics of everything.

The second issue is we were hoping not to have to swap core supports. But the rolled one looks to have a little bend on the side it landed on.
No big deal. Just some more things to unbolt.

And if we realize we are getting in over our heads with this body swap.
I know a guy that we can possibly pay to do the hard part of the wiring and actual body swap.
Cough Cough @the_fablab_ Just kidding. Well maybe, We'll see.

 

[the bodj]

Everyone loves to say "oh it just needs a body swap!" without realizing it's actually a pretty big project.

 

[59sled]

Everyone loves to say "oh it just needs a body swap!" without realizing it's actually a pretty big project.

Exactly. At one point, I thought cutting the roof off lower under the windows on the pillars. And welding the new roof on would be easier. But then trying to get door jams, to lineup and other issues it seem like more work.
The body swap is doable just takes time. Which I didn’t want it to take too much time because I don’t wanna piss off the neighbors. By doing this on the grass.

 

[LoganB]

91-92 are different from 93-94. You definitely are gonna want to swap EVERYTHING into the new body. Also, all of the relays and things in the rear are for automatic 4x4 tcase.

Personally I would swap the engine crossmember on the new one, then you can put the ttb on it. Then source a 4x4 manual trans and t case and eliminate so much electrical headache. You will be miles ahead, and if you can’t do it, Mikey will be able to get the fab parts back on it.