Swap in the d35 and 8.8 from the Ex also. And unless you already have a lift swap in the Ex springs also. Might also want to go with Ex t-case unless yours is a manual case.
Mines pretty much done, turned out well. Not as short as the BII but I'm real happy with the 2 door Ex chassis. Handles and rides better than the BII did and it's still short enough to make it real manuverable.
Besides needing to swap out the radiator support the gen 1 front bumper won't bolt on to the gen 2 frame. Either need a custom front bumper or mods to firr the stock bumper.
The problem with most chops is they're hack jobs. If you do a nice job they look really good, can be very functional, and look like a factory built truck.
http://www.flickr.com/photos/9970648@N06/sets/72157600761070252/
I believe you're wrong on this. 4 dr and 2 dr springs are not the same but they do interchange. The springs you thought were from a 2 dr must have been from something else.
The 4 door has heavier springs but no idea how much lift it'll give you. If your main leaf is OK I'd just get a set of 4 door springs and start adding a few leaves to your current spring pack and try it out, especially since you also want it a little stiffer.
I would think it'll bolt on but unless your '85 frame is bad why? Your '85 front bumper won't bolt to the '90 frame. The '90 will have a single high pressure fuel pump in the tank for EFI, vs the carb'd '85. If you want stronger axles for your BII just go find a junk 1st gen Explorer.
I'll second that. Why would anyone fix a d28. Even if the parts were free to fix it, I wouldn't want the risk of it breaking and leaving me potentially stuck without 4wd.
Read through this .... http://www.explorerforum.com/forums/showthread.php?t=123542
I've repaired that little plastic bushing on three different trucks.
Bedliner works nice but you lose the insulation. The problem with rubber over insulation is that if you get water under the rubber the insulation will never dry out. Bedliner comes in lots of colors also to match you interior.
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