Brother, I feel your pain.

I have the same truck.  Mine has the driver's door hinge problem that is
apparently fairly common.  This led to a lot of door slamming (because
the door doesn't line up properly) which in turn led to a latch that
keeps coming unscrewed and a door handle that's busted completely.  Of
course if I'd known the hinge was a common failure I could have bought
the kit 5 years ago when it started acting up and saved myself a lot of
trouble.

The driver's door hasn't closed properly in ages; if I'm ever in a wreck
I hope I roll onto the left side so that door will stay closed :-)

I also have manual windows (and no roof rack - how many Explorers have
no roof rack???) and have checked eBay for months without seeing a
single one of these handles listed.  Although if I replaced mine with an
OE handle I'd just break the new one in a couple months.

My plan is to remove the right handle, use it to make a template which I
can mirror and then make a handle out of 3/4" plywood.  Plywood can take
stress on any axis so I won't be as likely to bust the new handle.  If I
could get my hands on a scrap of no-void birch ply that would be sweet.

My '94 has so many problems it would cost more to fix them all than the
truck would be worth after the repairs.  Unfortunately, I don't have the
budget for a replacement.  I know all the idiosyncrasies so it's no big
deal for me, but I don't think anybody else could love this Explorer!