93 Ford Aerostar overland build.

[Jsherris]

So in 2017 I bought this 1993 ford aerostar xlt e4x4 for the Gambler 500 off-road rally. I am just getting into the overlanding scene as a hobby because from what I have discovered through many hours of research is overlanding is awesome and a great adventure. Currently I am converting it from passenger van to a camper van for woodland excursions. I have framed in a single bed with under storage for my gear totes, multiple fire extinguishers, led internal and external lighting. Plenty of water storage, recovery gear. I have built a spare tire carrier for the rear tow receiver as I had one located underneath in the original location and blew it out going over a downed tree haha. Spare fuel storage cooking gear and propane. I will be installing a roof rack later on. I have installed wheel spacers and oversized 235/75r15s. This weekend hopefully I will be installing a 2 inch coil spacer lift all around for a little extra ground clearance as getting high centered is really my only issue for most offroading I do. Does anyone have any suggestions on what gear I may need that I don't have currently or any build ideas to make this thing more live in friendly. Oh and I have manual maps, compass, and a cb radio for emergency communications. Thanks for the input guys. This is my first attempt at getting into the overlanding lifestyle but I've always wanted to do it. Any criticism is welcomed.View attachment 99097View attachment 99098View attachment 99099View attachment 99100View attachment 99101View attachment 99102View attachment 99103View attachment 99105View attachment 99104View attachment 99107View attachment 99106View attachment 99109View attachment 99108View attachment 99113View attachment 99110View attachment 99112View attachment 99111

 

[FreeRangeRedneck]

That’s awesome! Love it

 

[Low594]

Thats a great project! A buddy of mine just picked up a '96 xlt AWD 4.0, with a popup top. We've been looking into lift springs with little results. How did you fit the 235/75-15s? Stock suspension, some means of lift, inner fender clearancing? Do the tires rub when you have a wheel tucked?

We just put a new set of Cooper Discovery AT in the stock 225/70r14, but it desperately needs 15" steel rims and 28-29" ATs.
I found info(https://www.ford-trucks.com/forums/438621-aerostar-suspension-lift-3.html) on some front spring spacers(Specialty Products #1706), that result in 2" by all accounts and some diy spacers that'll lever the rear to match. The other thing we were going to do is replace the front upper ball joints and mount from under the A-arm, which should give another 1/2"-1" of down travel. Also going to see if we can find a suitable shock swap, that'll allow us to run Rancho RS9000s so we'll have adjustable dampening
View attachment 107503

 

[Jsherris]

Thats a great project! A buddy of mine just picked up a '96 xlt AWD 4.0, with a popup top. We've been looking into lift springs with little results. How did you fit the 235/75-15s? Stock suspension, some means of lift, inner fender clearancing? Do the tires rub when you have a wheel tucked?

We just put a new set of Cooper Discovery AT in the stock 225/70r14, but it desperately needs 15" steel rims and 28-29" ATs.
I found info(https://www.ford-trucks.com/forums/438621-aerostar-suspension-lift-3.html) on some front spring spacers(Specialty Products #1706), that result in 2" by all accounts and some diy spacers that'll lever the rear to match. The other thing we were going to do is replace the front upper ball joints and mount from under the A-arm, which should give another 1/2"-1" of down travel. Also going to see if we can find a suitable shock swap, that'll allow us to run Rancho RS9000s so we'll have adjustable dampening
View attachment 107503

so I've only installed a lift on the rear I cut out all four fender Wells with a sawzall for clearance and pounded back any metal that was still in the way the rear has a 1993 front coil spring suspension lift 2 inch spacer which was like 35 bucks on Amazon and also on the rear of my vehicle I have Gabriel air shock direct replacements so I have a thousand pound extra capacity and leveling capabilities on the rear without having to modify anything that is the best investment it was like 80 bucks. That way you can haul your stuff and not sag the rear end plus if I let all the air out of my shocks I still have enough clearance on the rear tires with the sawzall job I did I'll be it not
very pretty it is very functionable.

 

[Jsherris]

Sorry the rear coil spacers are from a 1993 Ford ranger kit

 

[Jsherris]

As well as for 2in wheel spacers 5 by 4 and 1/2 I believe same ones that fit a Jeep so that the tires and rims would come out far enough to not interfere with suspension components while turning

 

[Low594]

So no lift on the front?
And '93 Ranger front coil spacers, used on the rear with airshocks, but everything else oem?

I've been checking Craigslist for Jeep or ranger wheels, Toyota 5 lug should also fit, but each option have different back spacing.

 

[Jsherris]

So no lift on the front?
And '93 Ranger front coil spacers, used on the rear with airshocks, but everything else oem?

I've been checking Craigslist for Jeep or ranger wheels, Toyota 5 lug should also fit, but each option have different back spacing.

Yes everything else is original my wheels are just standard Jeep wheels off of like a 89 Jeep Cherokee I think so whatever the spacing of that is but as I said I put 2in wheel spacers on all four wheels

 

[Jsherris]

Yes everything else is original my wheels are just standard Jeep wheels off of like a 89 Jeep Cherokee I think so whatever the spacing of that is but as I said I put 2in wheel spacers on all four wheels

 

[Jsherris]

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