02/23/2023
Story time, or: Far too many words about a tiny, insignificant trim piece.
I broke a few plastic trim retainer clips while removing interior panels and needed to find replacements. This was no problem for most of the clips, as they were used on multiple models and are still made today (albeit in gray and black, so Mocha vinyl dye will come to the rescue once again).
The thing is, where the plastic trim meets the headliner, the Explorer used 1.5"/38mm long clips with .75"/19mm heads from the factory (which seem to have only ever been used on the 1st-gen Explorer, so are naturally no longer sold). I was able to find a similar Ford clip with the same shaft length/diameter with a 25.4mm/1" head all over the place, so figured I'd just have to buy some and build a jig to trim them down to match.
Turns out, after re-checking a screencap (movie on the left, my Explorer on the right), the builders of the screen-used cars must have run into the EXACT same problem, because they appear to have used clips with 1" heads in those spots. I scaled it against a 56mm width for the strip they're on, and they measure 25.4mm on the nose.
It's neat to run into the same issue the original builders must have had (broken clips, no replacement parts) and have to solve it in the same way.
P.S.: I'm not dead, but the A4LD transmission started doing what A4LD transmissions eventually do (read: not shifting), so a lot of the work has been back-burnered until that gets sorted out (read: I dump more cash into the hole). Hopefully sooner rather than later.