Your thinking is good/correct.If you give up Sas on Badlands you'll lose 4.7 gears (vs 4.46?) if you choose automatic trans, 5 35" GY tires, 5 beadlock capable wheels, slightly different Bilstein coilovers (supposedly a little less travel on the Sas version).
You'll still have front and rear lockers, advanced 4x4, sta-bar disconnect button, bigger differentials. All the good pieces to start a custom build.
4.7 gears are $400 each (front and rear) in Ford Performance parts catalog, plus installation.
I would choose aftermarket wheels, the price ford wants for the Sas wheels is way too much.
I'd be happy to have better tires than the GY's. They're not awful and have good traction, but they seem weak for off-roading.
I'm pretty sure I've seen people put 35's on a stock suspension Badlands without issue, especially if you're not going out on any moderate trails. If I was just looking for the look and/or starting out off-roading / overlanding, I'd just throw some nice wheels and 35" BFG AT's on the Badlands and call it a day. Once you get out there, you'll see which parts you want to improve for your use case.
If you were planning on modifying your Badlands Sas, I'd say the only real additional cost is the 4.7 gears and installation. I bet that is cheaper than the Sas package. And then I'd only be anxious on the 4.7 gears if I was planning on 37's (which I am).
I have Badlands Sas and chose Sas because I knew it would take a while for aftermarket to catch up and wanted to be able to do the trails I did in my previous 4x4. I wanted the extra height of the 35's to offset the low hanging bits of the Bronco.
I plan to replace most of the Sas package pieces (that are on top of Badlands) with aftermarket, except the 4.7 gears. (coilovers, wheels, and tires)
Oh, yeah. I keep forgetting the flares. They're probably more expensive than they should be, but not enough to change the $$ calculations.
My plan is to replace all suspension with an Overlanding setup (upgraded coilovers, UCA, tie rods, links). And I’m replacing the SAS wheels/tires with 37s and Black Rhino wheels.
I like the thought of just upgrading gears later and finding SAS flares.
My only rug after all said and done is I really really don’t want to give up MIC
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