best bet would probably be to call speedtech. I think I read somewhere that there front frame is lighter than oem. They also are making the aluminum spindles so you might be able to get everything from them. as far as rear suspension if you went with a G-link or something similar it would be lighter than the leaf's with the right setup.
nothing wrong with the explorer rear axle. it's strong and has disc brakes. not sure how much stronger it would be than the 10 bolt but it'll work. another option would be to just build up the 10 bolt a bit and get a LS disc brake setup from a camaro or ta.
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