Every Upgrade Earned Its Place

In our last blog, we shared the philosophy behind our Bronco build and why we’ve taken an OEM+ approach over the years.

Every change on this Bronco has a story behind it. Some came from lessons learned during rally training. Some came from breakdowns, unexpected challenges, or thousands of kilometers spent exploring the desert. Others were preventative upgrades designed to address known weak points before they became problems.

This isn’t a complete build sheet. It’s the story behind the components that made the cut. These are the upgrades that earned their place.

Suspension, Steering, and Strength

One of the first things we learned is that rally driving places very different demands on a vehicle than casual off-roading.

The stock Bronco suspension is very capable for everyday use and weekend trails. But once you start adding sustained speed, long days, and full gear loads, the limits start to show. To better handle that, we moved to custom tuned Radflo coilovers with DSC adjusters. The goal was never to build something extreme. It was to create a suspension that stayed predictable and controlled from the first kilometer to the last.

The front suspension relies on BTF Fabrication  upper and lower control arms and coil bucket gussets to improve articulation and reinforce areas that see increased stress during off-road and rally use.

Our relationship with Brandon and BTF Fabrication actually goes back years before we ever entered the Rebelle Rally. We had already used his suspension components on our other off-road vehicles and developed a lot of trust in both the products and the person behind them. So when it came time to build the Bronco, BTF was an easy choice.

From dedicated pre-runner/trophy builds to bullet-proof stock replacement kits, Brandon has built a reputation around strong, straightforward products designed to hold up in the harshest conditions. That philosophy aligns closely with our own approach to vehicle preparation. The additional articulation has improved the Bronco’s capability off-road, while the added strength provides confidence when the terrain gets rough.

One of our earliest lessons came the hard way. While rock crawling, we found ourselves high centered on an obstacle and trying to work through it. In the process, we broke a front CV axle. That led us down a path of experimenting with different solutions. We initially upgraded to aftermarket race axles, but continued dealing with fitment and four-wheel-drive issues. Eventually we switched to Ford Performance axles and haven’t looked back. They’ve been reliable, predictable, and exactly what we were looking for.

Once the axles were addressed, attention turned to other steering components. We upgraded to stronger Apex tie rods as a preventative measure and followed that with Teraflex steering rack bushings. Bronco owners know the steering rack can become a weak link once stronger tie rods are added, so reinforcing that system before it became a problem made sense for our build philosophy.

Even braking needed refinement. After years of use, the factory brake hardware started showing its age. The brackets weren’t holding everything as securely as they should, and the constant squeaking was a reminder every time we drove the Bronco. Upgrading to Power Stop brake components restored consistency and helped eliminate issues like uneven contact and the persistent noise.

More Than a Sway Bar

One of the most important components of our rear suspension is the RockJock Antirock sway bar. It helps keep the Bronco planted while still allowing the suspension to articulate when the terrain demands it. Combined with RockJock upper and lower control arms, a rear trac bar, and trac bar relocation bracket, the rear suspension is stronger, more predictable, and better suited to the demands of rally and endurance desert travel.

What we appreciate most about these components is that they don’t draw attention to themselves. They simply do their job. Whether we’re carrying a full rally loadout, navigating rough terrain during training, or spending long days exploring backroads, the rear suspension feels composed and confidence-inspiring.

RockJock has also been part of our rally journey for years. This fall will mark our fourth Rebelle Rally with their support, and their products have been a consistent part of the Bronco’s evolution throughout that time. In a sport where reliability matters more than almost anything else, that kind of long-term confidence means a lot.

Like many of the upgrades on this vehicle, the RockJock components weren’t added to make the Bronco look different. They were added because they made it work better.

Seeing and Being Seen

Something we’ve learned through rally and off-road travel is that lighting isn’t just about what you can see, it’s also about who can see you.

Our first lighting upgrades focused on safety. We added Baja Designs Squadron Pro amber lights and an S1 chase light for visibility in dust, traffic, and changing conditions. Amber lighting makes a noticeable difference when the desert gets dusty, and the chase light ensures we remain visible to others in low-visibility situations.

We also added a Baja Designs XL Linkable roof kit and XL80 A-pillar lights. We never plan to be caught out on course after sunset, but rally, travel, and desert life don’t always follow the plan. Whether it’s navigating back to camp, dealing with delays, or pushing through unexpected conditions, having reliable lighting is important. Baja Designs has earned a reputation for producing some of the best performance lighting in the industry, and for us the combination of output, reliability, and value made it an easy choice.

Then there are the lighting upgrades that solve problems you never expected to have. At one point, we broke a taillight because the factory housing stuck out far enough to make contact with the tailgate. The solution came in the form of Morimoto low-profile taillights. Their slimmer design eliminated the clearance issue while giving the rear of the Bronco a cleaner look. 

Armor and Body Upgrades

After our experience in the rocks we decided we needed a winch but unfortunately our stock bumper was not compatible. This led us to the Fab Fours stubby front bumper, which allows for winch integration without sacrificing approach angle. The Fab Fours rear premium bumper provides improved departure angle and added protection when terrain gets unpredictable. Adding the Warn Zeon 10-S was the finishing touch, a reliable recovery tool that’s ready when we need it and hopefully remains unused most of the time.

Not all lessons came from the trail. Our Bronco originally came with a soft top, which worked fine at first, but became noisy at highway speeds and we rarely opened up the top.

We experimented with a prototype hardtop, but it never fully delivered the insulation or durability we needed and ultimately didn’t make it to production. We eventually switched to the Armadillo Designs slant back hardtop and immediately noticed the difference. The improved insulation made long drives more enjoyable, while the gull wings and integrated shelving gave us much-needed organization for gear. As a bonus, the sporty slant back profile completely changed the look of the Bronco.

The Anderson Composites front and rear fenders came from another real-world lesson. At one point, we damaged one of the factory fenders while running larger tires. The Anderson fenders provided additional tire clearance while maintaining a sleek appearance that complements the Bronco’s factory body lines. They look right at home on the vehicle, which is exactly what we were after.

And finally, the vinyl wrap is both protection and identity. Designed by BlackHat Studios and installed by MV Autoworks, It protects the paint from years of desert pinstriping and road miles, but it also tells our story. It’s a reflection of where we’re from, our competitive rally spirit, and the partners who help make these adventures possible

Recovery and Self-Sufficiency

Of course, adding a winch is only part of the equation. The Factor 55 Borah recovery kit became the foundation of our recovery gear because it covers just about every situation we’re likely to encounter. Hard shackles, soft shackles, tree savers, tow straps, a kinetic rope, and a Rope Retention Pulley for changing pull direction all live in one organized package.

It’s one of those pieces of equipment that gives you confidence because you know the right tools are already with you.

Air management is handled by an ARB Twin compressor, mounted under the hood for reliability and quick access. Paired with the MORRFlate Air Hub and quad hose system, we can air all four tires up or down at the same time. The Air Hub automatically manages the compressor and shuts it off once the desired pressure is reached, making the process quicker and easier after a long day behind the wheel.

Lastly, for tire repair, we carry a GlueTread kit. What gave us confidence in the product wasn’t a marketing claim. It was seeing it tested in the real world. 

Tyler from MORRFlate put GlueTread patches to the test by intentionally damaging all four tires on his vehicle, repairing them, and then successfully completing the Rubicon Trail. That’s a level of confidence most people wouldn’t be willing to test for themselves. The relationship between the two brands makes sense. MORRFlate even includes GlueTread products in their own tire repair kits, which speaks to the trust they have in the product.

Hopefully we’ll never need to rely on these types of repairs on the trail but it’s reassuring to know the kit is there if we do.

The Right Tire for the Job

In our last blog, we talked about moving away from 37-inch tires and why bigger isn’t always better. That decision was only part of the story.

We later ran Kanati Mud Hogs for two years. They were tough, durable, and capable in rough terrain, but became increasingly noisy on the highway as they aged. In sand, their aggressive tread tended to dig rather than float.

When Pirelli expanded into off-road tires and began supporting Rebelle competitors, it caught our attention. Seeing a brand known for motorsport performance enter the off-road space felt worth exploring. We made the switch to 35-inch Pirelli Scorpion AT+  tires, and they’ve proven to be a strong fit for how we use the Bronco.

They offer improved road manners, reduced noise, solid sand performance, and reliable all-around capability across mixed terrain.

They’re paired with 17-inch Black Rhino Tusk wheels, chosen for their ability to maintain bead security at lower pressures. As a bonus, they pair perfectly with the Pirellis. We later learned that Pirelli has even showcased their tires on Black Rhino wheels in the past, which made the combination feel even more fitting.

The Little Things Matter

Not every upgrade comes from a failure or major lesson, some simply improve the experience. The K&N Dryflow intake and charge pipe fall into that category.

When we learned we could gain a little extra power from the EcoBoost by upgrading these components, it made sense for how we use the Bronco. Whether we’re climbing sand dunes in Glamis or hauling gear through the desert, a little extra performance is always welcome.

And if we’re being honest, hearing the turbos spool has been a fun bonus. The Bronco was almost silent before. Now you can actually hear them working, which adds a little extra character every time we get behind the wheel.

The K&N oil catch can was added for a different reason. EcoBoost engines are known to benefit from keeping excess oil vapor out of the intake system, so adding an oil catch can was a simple way to help protect the engine over the long term.

Built With Intention

Looking at the Bronco today, it’s easy to see the modifications. Suspension. Lighting. Armor. Recovery. Tires. What you can’t see are the lessons behind them.

As you can see, some upgrades came from a failure we never wanted to repeat, others came from recognizing a weak point before it became a problem, and some simply made the Bronco better suited for the way we actually use it.

Every component on this Bronco was chosen for a reason. While many talented companies built the parts that make up this vehicle, the vision behind how they all work together came from Jason, owner of Opt Offroad. He’s spent years helping customers build vehicles with purpose, and that same mindset shaped every decision made on this Bronco. Long before a single component was installed, he was researching, testing, and planning how each part would contribute to the vehicle as a whole.

The result isn’t the most modified Bronco you’ll find. It’s a Bronco built with intention.