My Expedition Modifications and Write-Ups

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bricekin

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Hello all!

This thread is going to be my build-log so to speak. I tend to start things, get excited, finish them, and regret not taking more pictures during the process. But, I tend to vividly remember things, so if there is something you see in the project photos I'll be posting here that you want more information on, don't hesitate to ask.

I have the feeling it is going to be a long and boring week here at work so I'll probably start linking pictures and giving information in between them tomorrow.

Here is a small, not so detailed list of things I've already done so you can have something to look forward to.
Audio
Video
Exterior
Interior Mods
Exhaust
PlastiDipping!
 
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toms89

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Any hints on your next project? :)

:smiley-face-popcorn
 
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bricekin

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Well... I'm picking up the rest of my hydro-graphic'd items tomorrow morning, so I am hoping to have re-assembly done before work. Then I've got a guy coming to install a vinyl windshield visor in the afternoon since I've made a few failed attempts at it.

I've got my 8" W7s for sale so I can get one of the new slim TW3s JL is shipping at the end of the month to put in the factory box.

Then, once my side work and snow plowing starts picking up again, I'll be doing projectors, Gotts style modification, and a tuner... Then I need to find some new wheels. Hopefully my A4 will go away soon too... that'll help with modification money.
 
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bricekin

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Ok... here goes... I'll try to remember the order in which I did things and give details of my experience doing it.

This is how it all started... just like this...
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The first thing I did was removed the ugly ass running boards.
Not difficult at all... I think there was 8-9 bolts on each side. Added to the look quite a bit but showed off the frame rails which were starting to flake paint... Sooo... out came the rustoleum.

This is about the best picture of it I have right now without the running boards... taken a couple days after I picked up this sweet toy.
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My truck came optioned with the Audiophile package and I was not pleased with the overall performance in the high frequency department. I replaced the factory tweeters in the front doors with some JL Audio XR series aluminum tweeters and inline high pass filters that I had lying around from a previous install. I mounted them up from behind, knowing that I would probably replace them again someday; I used hot melt glue to keep them in place. They added a little more crispness to the high end but still wasn't quite what I was looking for.

NO PIC

Since I still wasn't happy with the performance of the audio system I decided to try something I’ve been waiting to try in a Ford… Adapting 6.5” into the factory location. I started by making a 6x8 mounting ring out of ¼ wood with the internal cutout for a 6.5” then another 6.5” ring above it to help clear the frame of the speaker without hitting the factory mount which I didn’t want to cut. The 6.5” speaker I used was a JL Audio TR series mid, sourced from my left-over parts bin. Working in a stereo shop definitely has its perks. Even the factory speaker sits pretty close to the door panel so by the time I added half an inch of material behind the speaker; it was hitting the door panel. Using one of the JL grille rings was enough to get the panel off of the surround of the speaker. But… this still wasn’t enough for me and still more needed to be changed.

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ENTER MY 1996 THUNDERBIRD AFTER THE BREAK
 
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bricekin

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That was just the first attempt at better sound... Its on the third revision now and I'm waiting on a response from JL about another product to change it up again. There is a bit more coming in this thread. Just need another slow period at work to do it.

Your doors are actually a bit different than mine aren't they?
 

Scobinott

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Please keep the pics coming. Always looking for new ideas especially with sound systems and interior details!
 
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bricekin

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My 1996 Thunderbird Sport
This was a project that I had worked on for a couple of years but had only put 6k miles or so on and decided it was time to part with it since I didn’t drive it enough. I did a stereo system in it that consisted of a Pioneer AVIC-Z120BT, 2 sets of JL Audio ZR 5.25” components, a JL Audio HD900/5 five channel system amp, 2 JL Audio 8” W7 subwoofers, an Audiocontrol Matrix line driver, all JL interconnects, and JL 12ga wiring to every component.

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Shortly after I bought the truck is when I decided it was time to put the car up for sale as I would be driving either the Expy or my A4 far more often than the Thunderbird. Asking price was about 5k with all of the equipment in it and all the modifications I had done and 80k miles on the clock. She went nowhere quickly. So… I started stealing parts.

The first thing that was yanked from the car was the head unit. I used the PAC RP4-FD11 wiring harness which kept my steering wheel controls functional, gave me subwoofer inputs for the factory subwoofer, inputs for the factory AUX jack, and inputs to send audio from the Rear Seat Entertainment unit to the new head unit. The only inputs I chose to utilize at this time were the factory subwoofer and the factory AUX input. I also decided to run a set of three RCAs up to the RSE with bare wire on one end that could be used to solder to the input board on the end of the unit so that I could output audio/video from the head unit to the back since the AVIC unit is dual-zone capable. This actually worked out very well but disassembly of the RSE unit is a touch more difficult. It has VERY small hex head screws holding it together… after a half hour of using needle nose pliers… I decided to drill out all of the holes and pull the cover off and threw it to the side.

Pictures of my nearly finished radio harness and the modified RCA cabling for the RSE
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I was happy with this for a little while… But the Thunderbird still hadn’t sold after about another month. So out came the rest of the equipment to lower the price to near blue book.

A whole mess-o-wire came out of the Thunderbird
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I decided to dedicate a weekend to getting all my doors and interior trim apart and getting wires run and things all sorted. Once that weekend came, it was 90 degrees outside and what joyous fun that was. I started with one of my new favorite tools… a 8’ long section of RG6 cabling and some wire pulling lube (basically KY but comes in a gallon tub… maybe you can get KY in a gallon tub… I dunno). The first step was figuring out the best location for the amplifier. If you’ve got an Expy that’s nearly fully loaded and have never had one apart, I’ll be the first to tell you that stashing things, especially an amplifier, is not so much an easy task. Luckily my amplifier was just small enough that I could fit it under the radio inside the dash. Believe me when I say it was a tight fit once all the wire got to it.

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GAINMOB

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audio is the hook-up i need...i want to redo my doors and put my sub in a plexi-front box with LEDs and etch name on it
 
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bricekin

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I take it somebody likes JL Audio. :biggrin:

Sent from my Galaxy SIII Using Tapatalk2

JL Audio makes a fantastic product and being a dealer for them definitely doesn't hurt the situation.

I'm a diehard Rockford fan though. Some of the first equipment I've ever run so there is definitely a soft spot for them.

If I were going to do this again I would probably be using HAT (Hybrid Audio). I've listened to Scott's car and it is just absolutely INSANE.
 
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bricekin

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The second step was figuring out how to get the new wire everywhere. For the amp power cable, I ran it through the high side of the passenger firewall. I’m not exactly sure where because I couldn’t see it. I stuffed my white RG6 through and was able to pull it down from under the dash so that’s where it came through. I grounded the amp on the transmission tunnel close in front of the console. I ran 12ga from the amp to the crossovers which I located under the front seats. I also ran 12ga from the crossovers to the mid and tweeter in each door. The sub channel I ran an extra long 12ga to the rear so I’d have plenty of room if I needed to stuff the box behind the third row for some reason. Getting wire into the doors really wasn’t that much of a hassle with the exception of the driver’s door. I took about an hour running the amp power, about an hour running the driver’s door wiring, and about 30-45 minutes each for the remaining doors. For the driver’s door, I found it was necessary to remove the parking brake pedal from the kick area. I then had to pull the accordion boot from the jamb and cut slits in the end to allow more wire to comfortably fit through. I had to do this on all of the door boots. After doing this, and a liberal application of wire lube, I was able to shove my RG6 through the boot and pull my 2 sections of 12ga.

After getting the wiring terminated and ready for the speaker installation, I started to assemble each door. On the front doors, I dremeled out the factory tweeter hole and used the flush mount pods to install the tweeter to the front of the door panel. On the rear doors, I chose to use the door handle trim as my tweeter location so I wouldn’t have to cut a visible location on the actual door panel. I made my hole in the trim and a slightly larger hole in the door panel behind where the trim sits. I used the flush pods here again as well. When I put the 5.25s in the Thunderbird, I had a friend cut me out some 1/8” steel plates that adapted from the 5x7 to a 5.25” hole. I dynamat’d these on both the front and rear of the plates and installed the speakers to them. In the Expy, I had to add the grille trim to them in order to keep the surround from hitting the door panel. I bolted these in and put the interior back together.

In the first picture you can see the tweeter in the upper part of the door and the mid showing its face from behind the stock grille.
In the second picture you can see where I located the tweeter in the rear doors.
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One day I’d like to step up the size of the mids because I feel there is much more to be had than what the 5.25s offer. Not that the 5.25s disappoint, but they don’t have that kick of a 6.5 or 6x8.

Now we will dive into my discovery of a drug-like product, destroying everyone’s spare time, PlastiDip.

This stuff is outrageous. If you haven’t used it, go get a can from your local Lowes or Home Depot and try it. I don’t care what you use it on, spray it on your cat, you’ll think its awesome (NO don’t actually spray it on your cat… or your neighbor’s cat). A removable paint that protects whatever surface it is applied to. I’m addicted. Literally.

I hate the Pueblo Gold lower section on my truck and wanted an effective way of getting rid of it while having the option go to back and remove it.

ENTER PLASTI-DIP

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This stuff is so awesome it can actually be used to make a visor strip on your window in whatever shape you want! LOVE it.
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A video walk-around of the truck the day after I dipped it
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Window tint… 20% to match the rears
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I actually did an exhaust before the dip but I don’t have the sound clips or pictures of anything right now. I’ll do those later.
All of the dip has since been removed as I have a monthly package at my local Drive and Shine and use it on average 5 times a week. A section would come off here and there, I blame that partially on prep but also partially on using spray cans instead of gallons out of a gun. I’ll be doing it all again, but probably in gunmetal grey. I’ll also do the mirror caps to help tie in the look.
 
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bricekin

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Since I bought the truck, I’ve absolutely hated that the door handle trims were silver. They just seemed completely out of place… and I don’t like that. So out came the Flat Black Krylon Fusion paint.
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The wood grain was next to go. It is cool to have for a little while, and then it becomes a little much to look at. So I changed that too, using a process called hydro graphics. Basically, you have an image printed on a special film. You lay the film into the water, spray a chemical onto it that dissolves it into the water, and you literally dip your item into the graphic and it forms around the item and applies the image. I was originally thinking of doing a marble style dash but they didn’t have it in stock and I have a thing about ordering things. I just want to buy it and be done with it. They did however, have a smoky kind of skull pattern that had a marble-ish feel to it. So I went with that.

I sent them my shifter handles to start with just to get a feel for the pattern in my truck.
This is what I got back…
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Removing the wood from the doors seems like it might be difficult but it is actually pretty easy. Once the door panel is removed, you unscrew the arm rest from the panel. Once you have the arm rest out, the wood is screwed in from the underside of the arm rest.
Goodbye wood…
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And the result…
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bricekin

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The most recent thing I’ve done to date is the vinyl windshield visor. I made a couple failed attempts at doing it with vinyl so I had someone else do it. I love how it looks and I enjoy the function on of it.
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I’ve also had an exhaust done for awhile now and have been very happy with it as well. My uncle had a Flowmaster 50 with single 3” offset in/out that I had his shop throw on for me. I wanted loud but didn’t want 40 series loud. Our factory piping is 2.75” so adapters had to be made. I also purchased a 4” tip for it to give it a little extra flash. I’ll take pictures and a couple videos of the exhaust over the next week or so. It has a nice tone in the cabin and a awesome aggressive sound outside.

Coming soon:

The new snorkel thing that JasonLMarsh found for the Gotts style modification should be in this afternoon. So that will hopefully be installed by this weekend.

I’ll be revising my current subwoofer setup. I am tired of having to move the subwoofers if I want to put anything in the rear so I made a deal with JL Audio. They will be lending me the Expedition EL stealthbox to see if I can make it fit in my non-EL without any major modifications. If I can make it work, they will update the installation instructions and the website’s fit guide. For those not familiar, the JL stealthbox comes with a single 10” W3v3 with a single 2-ohm coil rated at 500W RMS. And for anyone not familiar with the stealthboxes at all, I highly suggest them and am always impressed with the output brought to the table by them.

I’m hoping that very soon I will have the funds to do the projector headlight retrofit as well. My A4 has factory projectors equipped and the difference is incredible. This is probably the modification I am most excited about.

When I bought my truck, there was an aftermarket Code Alarm remote start installed. The Code system is very similar to the system Ford was offering from the factory at the time. I’ll be replacing this system with either the Autopage C3-RS1100 which I have had on numerous other vehicles or I’ll be doing the Viper 5904/Python 594. I am leaning towards doing the 5904/594 though. Hopefully that will be late this spring.

I also want to do a tuner to firm up the shifts in the transmission and also to presumably get a couple more MPG. I’m thinking the SCT X3 will be in my future.

I've been waiting for a good deal on a factory rear backup camera assembly to pop up on ebay so I can play with adding it to my AVIC unit.
 
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bricekin

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I finally took some more pictures of some things that were previously done and a video of the exhaust.

Let's start with the exhaust. I re-used the factory pipes and replaced the muffler with a Flowmaster 50 series 3" single in/out with an offset outlet on each end. Finishing it off, I got a 4" Carriage Works Stainless Steel exhaust tip. I need a helping hand to get some video of how it sounds taking off/revving. I'll also work on getting a video inside so you can have an idea how loud it is inside.

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And the video
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I also did the 2010+ rear window wiper mod.
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jjbusa

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Looking good I was thinking of doing the wiper blade too

Sent from my SGH-I747 using Tapatalk 2
 
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bricekin

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I finally got around to doing the snorkel upgrade. Planned on it taking about 5-10 mins… took about 30-40 by the time I figured out what I actually had to do. The coolant line out of the bottom of the tank was keeping me from pushing the box as far out of the way as I wanted to. I pried the old section out into the fender area and was able to snake it out past the box and did the opposite procedure getting the new one in. I was assisted with vice grips when it came time to snap the new one into place. Throttle is a little more touchy and I do think that after I reset the computer, I may be getting slightly better mileage than before but this cold weather is killing it anyway so that’ll have to wait until spring before I see any real improvements I’m sure. The old one is actually so small that you can fit the flare and all into the mouth of the new one.

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I also finally placed my order for the JL Audio Expedition EL StealthBox (P/N SB-F-EXPDEL/10W3v3). I’m hoping to see this early next week. If I successfully install it with minimal modifications, JL will likely revise the product guide, and installation instructions to accommodate those of use that do not have the extended wheelbase.
 
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