Ultimate Performance: Inside the Build of a Fully Modified 2020 Ford Explorer ST

The 2020 Ford Explorer ST is already a high-performance SUV, boasting a 3.0L EcoBoost V6 and all-wheel-drive capability that makes it a powerhouse straight from the factory. But for true enthusiasts, stock is never enough. With the right modifications, the Explorer ST can be transformed into a street-dominating beast capable of taking on muscle cars and high-performance sports sedans.

This particular Explorer ST build features a perfect blend of power, handling, and durability—from massive turbo upgrades to race-ready suspension and braking systems. Whether you’re looking to build your own high-horsepower Explorer ST or just appreciate serious performance engineering, this guide breaks down each modification and why it’s essential.

Engine Performance: More Air, More Fuel, More Power

Whipple Intercooler – Keeping It Cool Under Pressure

One of the biggest limitations of the Explorer ST’s performance is heat soak from its stock intercooler. This build features a Whipple Intercooler, a massive upgrade that helps keep intake air temperatures lower even under extreme boost.

✔ Benefits:
✅ Lower intake temperatures
✅ Reduced power loss from heat soak
✅ More consistent power output

NGK Ruthenium Spark Plugs – Reliable Ignition Under High Boost

Upgrading to NGK Ruthenium plugs ensures stronger and more efficient combustion, especially when running higher boost levels. These plugs are ideal for tuned turbocharged engines, providing a cleaner burn and better reliability.

✔ Benefits:
✅ Improved ignition under high boost
✅ Reduced misfires and knock
✅ Longer lifespan than standard plugs

ZFG e50 and 93 Octane Tune – Unlocking the Full Potential

A proper tune is the key to extracting maximum performance from all of these modifications. This Explorer ST runs ZFG Racing’s e50 and 93 octane tunes, optimizing fuel and boost delivery for massive power gains.

✔ Benefits:
✅ More horsepower and torque
✅ Faster throttle response
✅ Optimized air/fuel ratio for better efficiency

Nostrum Stage 2 Injectors & Nostrum HPFP – Fueling the Beast

To support higher boost and ethanol content, this build features a Nostrum Stage 2 Injector upgrade paired with a high-pressure fuel pump (HPFP). These components ensure adequate fuel delivery for consistent and safe power.

✔ Benefits:
✅ Supports higher horsepower levels
✅ Ensures proper fueling with ethanol blends
✅ Improves reliability under heavy load

Stage 5 CRP Turbos – Massive Boost for Maximum Power

Arguably the biggest game-changer in this build, the Stage 5 CRP Turbos provide significantly more airflow and boost capacity over stock turbos. This upgrade is what truly sets this Explorer ST apart from the rest.

✔ Benefits:
✅ Drastically increased boost levels
✅ Huge horsepower and torque gains
✅ Faster spool and more efficient airflow

Intake & Exhaust: Letting the Engine Breathe

AFE Cold Air Intake & Velossa Tech Ram Air Snorkel – Maximizing Airflow

A turbocharged engine needs as much cold air as possible, and this setup is designed to maximize intake efficiency. The AFE Cold Air Intake improves airflow, while the Velossa Tech Ram Air Snorkel ensures that the turbos get a direct blast of cold, dense air.

✔ Benefits:
✅ Increased airflow for better turbo response
✅ Improved engine efficiency and power
✅ Enhanced turbo sounds and induction noise

FENFAB Charge Pipe & Downpipes – Improving Flow and Response

The FENFAB Charge Pipe ensures smoother airflow between the turbo and intake manifold, reducing pressure drop and improving throttle response. Meanwhile, the FENFAB Downpipes improve exhaust flow, reducing backpressure and allowing for quicker turbo spool.

✔ Benefits:
✅ Less restrictive airflow
✅ Faster turbo spool and response
✅ More aggressive exhaust tone

Thermal R&D 3” Exhaust – A More Aggressive Sound and Performance Boost

An upgraded exhaust system is essential for reducing exhaust restrictions and creating a deeper, more aggressive tone. The Thermal R&D 3” exhaust system complements the downpipes, providing improved flow and a mean sound without excessive drone.

✔ Benefits:
✅ Better exhaust scavenging for improved power
✅ More aggressive sound profile
✅ Lightweight construction for less weight

TIAL Q50 Blow-Off Valve – Turbo Sound & Longevity

The TIAL Q50 BOV helps release excess boost pressure, preventing compressor surge while also delivering that iconic turbo “whoosh” sound.

✔ Benefits:
✅ Prevents turbo damage from excess pressure
✅ Faster throttle response and turbo spool
✅ Signature turbo sounds

Drivetrain Upgrades: Handling All That Power

RSA Raybestos 10r60 Stage 1 Transmission Build & Billet Flex Plate

With massive torque increases, the Explorer ST’s stock transmission won’t hold up for long. This build includes an RSA Raybestos Stage 1 transmission upgrade, improving clutch durability and shift performance, along with a billet flex plate for added strength.

✔ Benefits:
✅ Stronger transmission components for higher power
✅ Smoother and faster shifts
✅ Improved reliability under high boost

Suspension & Handling: Keeping It Planted

BC Racing Coilovers & Adjustable Suspension Components

With the power nearly doubled, proper suspension upgrades are crucial for handling. The BC Racing Coilovers allow for adjustable ride height and damping, while the Steeda and FENFAB components fine-tune suspension geometry.

✔ Suspension Mods & Benefits:

Braking: Stopping Power to Match the Speed

SuperForged Big Brake Kit – Braking Confidence at High Speeds

With higher horsepower and torque, stopping power is just as important as acceleration. The SuperForged Big Brake Kit provides larger rotors and high-performance calipers, significantly improving braking force and fade resistance.

✔ Benefits:
✅ Increased stopping power for high-speed runs
✅ Better heat dissipation under heavy braking
✅ Improved pedal feel and control

Final Thoughts: The Ultimate Explorer ST Build

This fully modified 2020 Explorer ST is a true high-performance SUV, capable of delivering supercar-level acceleration while maintaining daily drivability. With a perfectly balanced setup of turbo upgrades, fueling, tuning, suspension, and braking, it proves that the Explorer ST is more than just a fast family hauler—it’s a serious performance machine.

Estimated Performance Gains

🚀 What’s next for this Explorer ST? Could we see an 800+ HP AWD sleeper SUV take down Hellcats and Teslas? Only time will tell! Stay tuned for more updates on this incredible build.