Corned 2.0: Transforming the 2020 Ford Explorer ST into a 760+ HP Powerhouse

The Ford Explorer ST has always been recognized for its blend of performance and practicality. However, for some enthusiasts, the stock performance is merely a starting point. Enter “Corned 2.0,” a 2020 Ford Explorer ST that has undergone a comprehensive transformation, pushing its capabilities beyond conventional limits. This build not only showcases the potential of the Explorer ST but also serves as an inspiration for those looking to elevate their vehicle’s performance.​

Genesis of Corned 2.0

The journey of Corned 2.0 began with an unfortunate event where the stock connecting rods failed under increased boost pressures, leading to significant engine damage. This incident underscored the necessity for robust internal components capable of handling elevated performance demands. Determined to overcome this setback, the owner embarked on a mission to rebuild the engine with fortified internals, aiming for a power output exceeding 760 horsepower on E85 fuel.

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Engine Overhaul: Building a Race-Ready Powerplant

Starting with a fresh OEM Ford 3.0L Ecoboost Motor, it was stripped down and sent off to the machine shop to undergo upgrades. Upon Blueprint and Balancing of the block, the new engine returned to AED Racing. To achieve the ambitious power goals, the engine underwent a meticulous rebuild with high-performance components:​

• ZFG Racing Spec Wiseco Pistons: Specially designed, developed and tested for high-boost applications. These forged pistons offer enhanced strength and durability, essential for high-boost applications.​

• SAENZ Performance Connecting Rods: Known for their resilience, these rods are designed to withstand the stresses of increased horsepower and torque.​

• Kelford Valve Springs Set: Upgraded valve springs ensure valve control at higher RPMs, preventing valve float and maintaining engine integrity.​

• EMS Spec Head Stud Kit: Provides secure clamping force, crucial for maintaining head gasket integrity under high boost.​

• ZFG Main Support Girdle and Main Studs: These components reinforce the engine block, preventing distortion under extreme conditions.​

• FENFABrication Performance Oil Pan: Designed to improve oil circulation and cooling, essential for high-performance engines.​

Collectively, these upgrades transformed the engine into a robust platform capable of handling 35 pounds of boost and delivering over 760 horsepower on E85 fuel.

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Forced Induction and Fuel System Upgrades

Enhancing the engine’s breathing and fuel delivery was paramount to achieving the desired performance:​

• CR Performance Stage 5 Turbos: These Explorer ST upgraded turbochargers significantly increase airflow, enabling higher boost levels and substantial power gains.​

• Nostrum Stage 3 Fuel System with Stage 3 Injectors: This comprehensive fuel system upgrade ensures adequate fuel delivery, crucial when running E85, which requires approximately 30% more fuel flow than gasoline.​

• AFE Momentum GT Cold Air Intake System: Improves air intake efficiency, allowing the engine to breathe better and enhance combustion.​

• Turbosmart BOV Kompact Dual Port: Ensures optimal boost pressure management and protects the turbo system.​

These modifications work synergistically to maximize the engine’s potential, ensuring reliability and performance.

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Exhaust and Cooling Enhancements

Managing heat and exhaust flow is critical in high-performance applications:​

• Whipple Mega Cooler Intercooler: This large-capacity intercooler effectively reduces intake air temperatures, enhancing performance and preventing heat soak.​

• FENFABrication Performance Test Pipes / Downpipes: These components improve exhaust flow, reducing backpressure and allowing the turbos to spool more efficiently.​

• Thermal R&D 3″ Cat-Back Exhaust System: Enhances exhaust flow and produces a more aggressive exhaust note, complementing the vehicle’s performance capabilities.​

These upgrades ensure that the engine operates within optimal temperature ranges while efficiently expelling exhaust gases.​

Transmission and Drivetrain Fortification

To handle the increased power, the transmission and drivetrain received significant upgrades:​

• RSA 1060R Stage 1 Transmission: Reinforced to withstand higher torque outputs, ensuring smooth and reliable power delivery.​

• Suncoast PRO-LOC 10R60 Torque Converter with a 3000rpm Stall: Optimizes launch performance by allowing the engine to reach its power band more quickly.​

• Meziere Flex Plate: Provides a durable connection between the engine and transmission, capable of handling increased power.​

These enhancements ensure that the drivetrain can reliably transmit the substantial power to the wheels without compromise.

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Suspension and Chassis Improvements

To complement the powertrain upgrades, the suspension and chassis were also addressed:​

• H&R Lowering Springs: Lower the vehicle’s center of gravity, improving handling and reducing body roll.​

• ID Speed Rear Differential Brace: Strengthens the rear differential, preventing flex under high torque loads.​

• FENFABrication Rear Subframe Lockout Kit, Vertical Link, and Rear Toe Links: These components enhance rear-end stability and alignment, crucial for high-speed stability and cornering performance.​

These modifications result in a more planted and responsive driving experience, essential for harnessing the vehicle’s increased power.​

Wheel and Tire Setup

Translating power to the pavement requires an effective wheel and tire combination:​

• Weld Racing Ventura 5 Beadlock Wheels (18×10): Lightweight and strong, these wheels are designed for high-performance applications.​

• Mickey Thompson ET Street S/S Tires (275/45-18): Provide exceptional grip, essential for effective power delivery and acceleration.​

This setup ensures maximum traction, reducing wheel spin and improving launch performance.

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Tuning and Electronics

Optimizing the vehicle’s electronic systems was crucial to integrate all modifications seamlessly:​

• ZFG Custom Tuning with DSM Upgrade
  At the heart of Corned 2.0’s performance is a custom calibration from ZFG Racing, one of the most trusted names in tuning for the Explorer ST platform. With the DSM (Drive Strategy Module) upgrade, ZFG was able to fine-tune parameters like boost pressure, fuel delivery, spark timing, and transmission behavior to create a tune that makes the most of the hardware upgrades—especially on E85.
  The result? A high-performance daily-driver capable of hitting full boost (35 psi) with smooth throttle response, consistent power delivery, and excellent drivability.

• AED RTD+ Device & HP Credits
  Used for flash tuning, data logging, and remote support, the RTD+ provides a direct connection to the ECM. Combined with HP Tuners software and support credits, this makes custom tuning faster, more efficient, and precise—key to unlocking the full potential of the new engine and turbo system.

• NGK Spark Plugs
  With the amount of boost and power Corned 2.0 produces, reliable ignition is critical. High-performance NGK Ruthenium spark plugs were installed to ensure consistent combustion and minimize the risk of misfires under high load and temperature conditions.

E85 – The Game Changer

One of the biggest power unlocks in Corned 2.0’s journey has been the switch to E85 ethanol-based fuel. While E85 has less energy per gallon than gasoline, its higher oxygen content and cooling properties allow for aggressive timing and significantly more boost without knock.

With Nostrum’s Stage 3 Injectors and HPFP, the fuel system is capable of handling the volume demands of E85 even under full boost. Running ethanol at 35 psi helped push the final numbers past 760+ wheel horsepower, with torque figures climbing into the high 700s as well—truly supercar-level output in an AWD, three-row SUV.

Real World Results

All this power isn’t just for the dyno. Corned 2.0 is an all-wheel-drive monster that hooks, launches, and moves. Whether it’s at the drag strip or dominating in roll racing events, this Explorer ST surprises many who underestimate the platform. Thanks to the Suncoast torque converter with a 3000 RPM stall, it leaves the line with authority. The Mickey Thompson ET Street S/S tires ensure that all four corners put power down reliably.

On the street, the upgraded suspension—especially with components like FENFAB’s toe links, vertical links, and rear subframe lockout kit—keeps the chassis tight and planted. Despite the 760+ HP power figure, the SUV is remarkably composed and can be street-driven with confidence.

Unique Styling and Function

Corned 2.0 isn’t all go and no show—it also features several subtle yet functional upgrades that add to its aggressive stance and track-ready performance:

• Weld Racing Beadlock Wheels give it that unmistakable drag-strip aesthetic while serving an important purpose—locking the tire to the wheel at high torque loads.

• H&R Lowering Springs enhance the sporty silhouette while improving center of gravity and handling.

• The Turbosmart BOV not only helps control boost but adds an unmistakable whoosh under throttle lift, letting everyone know this isn’t your average SUV.

• The engine bay is decked out with performance hardware and quality fasteners, and under the vehicle, everything from the FENFAB Performance Oil Pan to the Thermal R&D 3” exhaust speaks to serious attention to detail.

The Journey from Stock to 760+ HP

Corned 2.0’s transformation is nothing short of legendary. What began as a clean 2020 Ford Explorer ST evolved—through trial, error, and an unfortunate rod failure—into one of the most powerful Explorer STs in the country. Here’s a simplified timeline of the key phases:

Why Corned 2.0 Matters to the Explorer ST Community

Corned 2.0 isn’t just a one-off science project. It represents what’s possible when enthusiasts push the envelope and build their SUV with both passion and purpose. For Explorer ST owners wondering how far their platform can go, Corned 2.0 answers with authority.

It also demonstrates the importance of choosing quality components, reputable tuners, a race shop that knows what they’re doing and being ready to invest in the right supporting mods.

Builds like this set the benchmark, not just in power, but in consistency, drivability, and long-term reliability.

Built by Legends – AED Racing and Cornfed 2.0

Cornfed 2.0 didn’t just become one of the most powerful Explorer STs on the road by accident—it was brought to life by the hands and minds of AED Racing, a shop known for pushing the limits of Ford performance with precision, passion, and purpose. With decades of experience in building high-horsepower platforms, AED Racing took this once stock Explorer ST and transformed it into a street-legal monster with track-ready reliability.

From blueprinting the built motor with Wiseco pistons and SAENZ rods, to dialing in the ZFG-powered calibration on E85, AED Racing left no stone unturned. Every bolt, every sensor, every component was meticulously selected and installed to work in harmony—proving that proper engineering meets peak performance when you’re working with a shop that truly understands the platform.

Cornfed 2.0 stands as a rolling testament to AED Racing’s commitment to building vehicles that don’t just make numbers—they make noise, break records, and inspire a community of enthusiasts who know what it means to go all in. When you want it done right, you go to the best. And Cornfed 2.0? It was built by the best.

The Final Verdict

With its track-ready stance, bulletproof drivetrain, and monster power curve, Corned 2.0 is a rolling testament to what’s possible with the Ford Explorer ST. It’s not just fast “for an SUV”—it’s just plain fast, period.

From the street to the strip, this 2020 Explorer ST is redefining expectations of what a three-row crossover can do when it’s been built with vision, quality parts, and expert tuning.

Specs Summary: Corned 2.0 Explorer ST

If you’re an Explorer ST owner dreaming of massive horsepower and real performance on the track or the street, Corned 2.0 is the blueprint. It’s a reminder that with the right vision—and a few forged rods—anything is possible.

Want a build like Corned 2.0? Stay connected with the Explorer ST community at ExplorerST.Club and follow leading Explorer ST builders like AED Racing and tuners like ZFG Racing to start your journey.

Let’s go fast, boost bros. 💪🔥