F100 + Ford Explorer Brakes: The Swap Nobody's Tried

We're back on the F100 to Ford Explorer chassis swap — this time tackling the brake booster, master cylinder, and a custom pedal assembly that mixes Ford Explorer parts with the factory F100 setup. Plus, handmade steel door sill plates because sometimes you need a creative break. This 1957 Ford F100 sits on a shortened, flipped 2008 Ford Explorer chassis — keeping the factory IRS rear suspension in its original location. It's a swap we haven't seen done quite this way before. In this episode: I fabricate 18-gauge steel door sill plates from scratch, then move into mounting the Ford Explorer brake booster onto the F100 firewall. That turns into a full pedal assembly redesign — blending the Explorer's sensor-equipped brake pedal with the factory F100 pedal geometry. We press, cut, weld, and test-fit until it all lines up. If you're researching an F100 Explorer swap, an IRS retrofit, or just like watching real fabrication problem-solving (including the parts that don't go as planned), this one's for you. ⏱ Timestamps 0:00 – Intro / project update 1:09 – Fabricating steel door sill plates 3:02 – Prepping the firewall for the Explorer brake booster 5:00 – Modifying mounts & welding extensions 7:44 – Combining Explorer sensors with F100 pedals 10:09 – Dialing in final pedal geometry 16:09 – Using the drive-by-wire gas pedal 17:46 – Creating a modular pivot pin 19:06 – Pressing holes & final assembly 🔧 New shop t-shirts are live on the website www.muggcustoms.com Thanks to Arc Captain for keeping us stocked on welding and cutting gear. Save money with them using this promo code: MUGGLIFE (all caps) #F100 #FordExplorerSwap #CarFabrication