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I'm looking foreward to seeing your progress! I have a 94 ranger with 3.45 and believe me they're not that bad in town. Instead of a gear swap and lowering, I would look into finding an explorer rear axle with 3.45s. If I remember correctly they're axle-over-spring and the springs and all will bolt right in so you'd. be killing 2 birds with one stone, without the pain of tearing a rear end apart plus they were available with rear disc brakes, if that's your thing. As far as the aerocap, I can't really help you there I just take my gate off (easier) I would also love to see your grill blocks and future mods as you go. Good luck
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