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For peace of mind, I did this upgrade. Thanks to my boss (with skills, shop, and equipment) the job was relatively easy. It took longer to make decisions on method than actually doing the work!
I got the headrests and plastic guides from a 1999 Expedition (second row) that was just about to be crushed at the scrap yard. (A kind hi-hoe operator let me pull them before he rammed his claw through it.) The tubing was also from the scrap yard $6 for all!
Part 1 - Dis-assembly
First, peeling off the fabric. Unclip the J-hook plastic strip on the bottom. Then work the fabric upwards. Pry out the staples holding the carpet tab to the wood panel.
The cover is one-piece, it was tight, but I moved carefully, rolling/peeling and working it up off the seat. be firm with fabric. it will stretch around the foam. I found 'rolling' it helped in the tightest spots
my 3-year old helping me take apart the seat! hog rings holding the front fabric and foam onto the frame. I tried working with these left in place, but ultimately it's worth it to remove them right away for welding.
wood back panel exposed. It is held by self-threading screws. remove easily. main frame shape, one of many designs (based on other's photos)
Part 2 - Fabrication
Not the best pictures, I was working and excited, so I forgot to stop and snap.
We laid out locations and marked the big tubing. Check your locations against the fabric - there's an offset in the seat back frame. It's not centered. I based my position on the seams in the fabric. The passenger side was 1/2" different than the driver's side. bare frame exposed after removing hog-rings. much easier to work on in this position.
My first time with a Bridgeport! -carving out slots for the plastic receiver tabs on the top. The tab stops it from turning.
I wanted the upright tubing as far forward as possible, which required cutting into the big main frame tubing. I didn't want to cut too much, so we aimed for 1/3 depth. I used a grinder to eat out a U-shaped cavity for the 3/4" upright tubing to rest inside and have good welding area. Checking depth of tube recess into main frame. I went about 1/3 way through the main frame tubing.
Sparking away. The bottom end of the upright tube - we flattened and welded to the outside of the main frame.
Here's the top, after adding foam back in. Welded both sides of the tubing and didn't blow through the stainless - my boss has skills!!
We had to carefully make sure the slotted ends were oriented proper. For the headrests and receivers - this meant facing inwards, towards eachother.
Part 3 - Assembly
Back in the house (I did this in January when it was cold outside!)
Here's a good tip from FTE forums: using a hole saw, drill set to reverse. It carved the foam perfectly around the protruding vertical tubing.
You can also see, barely, the shims I put behind the wood panel. The vertical tubing was an even plane across all four pieces, but they didn't match the main frame. So I used different sized shims at top and bottom to correctly space the gap between the panel and main frame. (The panel fastens to the main frame.)
Stretching the fabric, same as before. Move carefully, but firmly. It's tough stuff. I found it easier to do one side at a time, working in steps, pull/roll/tug. I sort of turned it inside-out and un-rolled it over the foam. It was snug and tight.
We then stretched the fabric upholstery over the whole thing. My wife is a sewing expert and suggested NOT cutting holes in the fabric. Instead she felt the tubing, cut tiny X-shaped slits in the fabric, and then forced the tubing through it.
Here's the receivers going into the tubing vertical pieces.
Top view. Yes, the receivers protrude slightly. It was unavoidable to get the height I wanted for the headrests.
Results:
I'm very happy with how it turned out. They tuck in the seat nice when it's folded down. There's good clearance from the second row seat backs.
They don't block my rear-view much. This is fully raised position:
And - headrests lowered, down position.
The great blessing was the matching material, color, and age of the headrests themselves.
Thank you for all the info. and encouragement I gained from this site. This was a major project for me personally. My Ex is nothing special but I feel much safer putting my kids back there. We're eager to take it on a road trip now! The kids are coming up with compartments, baskets, and such for each to create their own 'nest' in the back for long car trips. Onward!
Well, the time has come...I'm going to sell the Excursion.
This seat was a good project and valuable! I want to offer it here on FTE instead of tossing it with the Ex. I don't think it would be appreciated as much anywhere else.
Here's a link to my listing here on the Marketplace. Let me know if you're interested! https://www.ford-trucks.com/forums/market/1753399
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