From Stock to Showstopper: The Secret Behind Our SEMA 2025 Bronco Build

When we first picked up a Ford Bronco Outer Banks back in February of 2025, it was nothing more than a stock rig with potential. No lift, no oversized tires, no flashy accessories — just a blank canvas sitting in our shop, waiting for a purpose. To most people, it looked like an everyday Bronco. But to us, it was the foundation for something greater — a chance to push limits, challenge expectations, and create a build that blurred the line between trail-ready performance and show-stopping design.

The early months were all about exploration. We spent time learning the platform inside and out, experimenting with smaller upgrades, and shaping a vision for what this Bronco could become. Every idea, every sketch, every late night in the shop brought us closer to something that felt special — even if, at the time, it was still just potential. We knew we wanted to build this truck up to represent our brand. But we had no intentions of going big right away.

Then came September, and everything changed. We got the call — our Bronco had been selected as one of the ten finalists for the SEMA 2025 TORA Trail Showcase, competing not just for recognition but for Feature Build of the Year. Suddenly, our steady build pace turned into an all-out sprint. What had been a summer project became a full-blown race against time.

With just under two months to completely transform the truck, every day and night counted. Fabrication, suspension, lighting, armor, interior — all of it had to come together seamlessly before the November 1st deadline. It wasn’t just about finishing the build; it was about creating something that stood out in a sea of extraordinary machines.

This is the story of how a stock Outer Banks Bronco went from ordinary to unbelievable — and how a tight deadline, a bold vision, and a little bit of madness turned it into something nobody expected.

Build Overview: Turning Vision into Reality

When it came time to bring our Bronco vision to life, every component had to serve a purpose — form and function working hand in hand. With the clock ticking toward SEMA, we couldn’t afford a single misstep. Every bolt, bracket, and panel was carefully chosen to enhance performance, durability, and style. Below is the full breakdown of what went into transforming our 2023 Ford Bronco Outer Banks from a factory ride into a TORA Trail Showcase contender.

Suspension — Built to Perform, Tuned to Conquer

The foundation of any capable off-road build is its suspension, and ours is nothing short of elite. Partnering with Icon Vehicle Dynamics, we equipped the Bronco with a full Icon CDXS front and rear coilover system, billet upper control arms, and billet rear upper and lower links for maximum strength and articulation.
To tie it all together, we added Icon HD tie rods, a bump stop spacer kit, and an adjustable track bar to handle the most demanding terrain. Supporting components like the Rock Jock track bar relocation kit, JKS Max Tire Kit, and ADS sway bar disconnect links make this system equally ready for high-speed desert runs and technical crawling.

Armor — Protection Where It Matters Most

The Bronco may look sleek, but underneath it’s a fortress. We went all-in with RCI Offroad armor, covering everything from the engine, transmission, and fuel tank skid plates to crossmember, differential, and LCA protection.
RCI’s rear shock guards, 5-degree sliders, and pinch weld kit ensure the rig can take the hits without hesitation. Finishing it off, we equipped the bronco with a DV8 Offroad Competition Series front bumper, Spec Series rear bumper, and trailing arm skid plates — creating a bulletproof undercarriage built to survive any path that stood in its way.

Lighting — Turning Night into Day

Visibility is everything, especially when the trails go dark. For this build, lighting wasn’t just an upgrade — it was a statement. We turned to Diode Dynamics for a complete overhaul that delivers both power and precision across every zone of the Bronco.

The centerpiece of the setup is our custom 11-pod SSC2.0 Max Power Crosslink light bar, mounted seamlessly into the TrailRax roof rack. This system delivers a massive wall of light output — flooding the trail ahead with crisp, controlled illumination that makes night runs feel like daytime. Every pod is precision-aimed for perfect coverage, turning the roof rack into a functional and aesthetic powerhouse.

Supporting the Crosslink are Diode Dynamics SS3 Max fog lights, a SS3 and C2.0 Max combo ditch light kit, the newly released Stage Series 20” front light bar, and RGBW rock lights that add visibility and style underneath. The system extends to Pro Amber SSC2.0 roof rack zone lights, a custom made SSC2.0 Pro Amber rear chase bar, and a dedicated cargo lighting setup, all powered and managed through the Diode Dynamics D Switch Power Panel for clean, intuitive control.

Completing the package are Form Lighting headlights, Morimoto XB LED tail lights, and a custom third brake chase light featuring Baja Designs LEDs — ensuring the Bronco shines from every angle.

And for functionality where it counts, we added Diode Dynamics rock lights tied into a pressure switch for our rear gullwing setup — automatically illuminating the cargo area the moment the gullwing doors open. Inside, a custom Diode Dynamics Rock Light cargo lighting system provides bright, even coverage for organizing gear and loading up at camp after dark.

Exterior Products — Bold Looks, Rugged Function

Every line of this Bronco was redefined with a mix of aggressive design and premium craftsmanship. Anderson Composites brought carbon fiber style with a custom hood and wide-body hi-rise front and rear fenders, giving the truck its signature stance.
DV8 added front wheel well liners and a rear tire carrier, while TrailRax contributed a robust roof rack to support the lighting and gear setup. 

To enhance on-trail utility, we integrated the Apex Designs Kit, featuring the Compact Reel System (CRS), Precision Tire Inflator, High-Flow Chuck, Banjo Bolt, and braided air line, paired with an Adventure Labs roll bar mount to perfectly position the CRS within reach. The setup pairs flawlessly with the ARB Twin Compressor, giving us the ability to air up or down quickly during trail runs.

We also outfitted the Bronco with ROAM 83L storage cases, mounted securely for easy access to tools, recovery gear, and essentials on the move. Durable and weatherproof, these cases blend perfectly with the overall design — adding both function and form for overland adventures and long-haul trips alike.

Mounted alongside them, a set of ARB Pro TRED recovery boards ensure we’re ready for whatever the trail throws our way. Whether it’s sand, snow, or mud, they provide quick and reliable traction when the terrain turns tough — a must-have for any serious off-road setup.

Finally, Armadillo Designs delivered a custom hard top with molle panel gullwings and a custom headliner to compliment our interior. This rack was paired with custom brackets made by Armadillo Designs to help the TrailRax roof rack to pair perfectly with this one of a kind Hard Top. Then we topped the bay with a clean engine cover from JCR, blending ruggedness with refinement from every angle.

Interior Products — Comfort Meets Capability

Inside, the Bronco is as refined as it is rugged. Premium sound comes courtesy of Focal fiber speakers, an Audio Control subwoofer, and a JL Audio amplifier.

Interior upgrades include DV8 overhead and door molle panels, a rear cargo barrier kit, BuiltRight Industries rear seat molle panels, and Clazzio custom leather that elevates comfort to a new level.
For this build, we partnered with Clazzio to create custom leather seating featuring our shop’s logo embroidered into the headrests, giving the cabin a truly one-of-a-kind look that represents who we are and what this build stands for.

For driver convenience, a Wolfbox G900 Tri Pro mirror and BulletPoint Mounting Solutions dash kit provide modern tech and secure mounts for navigation and comms — making sure this Bronco is trail-ready inside and out.

One of our favorite additions is the custom rear cargo build-out, engineered with T3030 extruded aluminum. This setup features a custom sliding shelf designed specifically for our Iceco IPT20 fridge, providing quick access to refreshments and essentials on the go. The lower compartments offer additional modular storage space for tools, recovery gear, and outdoor essentials — keeping everything organized and ready for our next adventure.

Performance Products — Power, Precision, and Pure Capability

When it comes to performance, this Bronco was built to back up its looks with serious capability. From drivetrain to power delivery, every upgrade was selected to maximize reliability and control in the harshest conditions — especially with the move to massive 38” Nitto Ridge Grappler tires.

We started from the ground up with a complete Ford Performance axle upgrade, swapping in 4.88 gears front and rear for improved torque, throttle response, and crawl ratio. This gearing perfectly compensates for the added rotational weight and rolling resistance of the 38s, restoring power and drivability both on the highway and off-road. The front unit also features a Ford Performance e-locker, giving us true on-demand traction when the terrain gets technical.

Up front, the steering and driveline were reinforced to match the new load demands. Icon Vehicle Dynamics HD tie rods deliver unmatched steering strength and precision, while Ford Performance HD CV half shafts handle the increased torque and articulation that come with larger tires. To tie it all together, a custom-built driveshaft from Adams Driveshaft ensures flawless power transfer through the drivetrain — purpose-built to handle the added stress of 4.88 gearing, aggressive terrain, and the weight of 38-inch rubber.

Cooling and airflow upgrades keep the 2.7L EcoBoost running strong under pressure. The Bronco is equipped with UPR dual catch cans, a Mishimoto intercooler, AFE hot and cold pipes, and an Injen cold air intake feeding a CSF high-performance radiator. Together, these components reduce intake temps, improve throttle response, and keep the power consistent when the trails heat up.

A Flowmaster American Thunder exhaust adds a deep, refined tone while freeing up exhaust flow, and the Diablo Sport Pulsar XT tune optimizes the power curve for responsiveness and efficiency. When it’s time to slow it all down, the Baer 13.5” 6T brake kit delivers confident, controlled stopping power — crucial when managing the weight and momentum of 38-inch tires.

To top it off, PPE rear differential and transmission pans add cooling and protection for long-term reliability, ensuring this drivetrain performs just as well on long expeditions as it does on the SEMA floor.

This setup isn’t just about horsepower — it’s about balance, strength, and precision. Every part of this system was engineered to work in harmony with the 38s, giving the Bronco the torque, traction, and control needed to perform flawlessly on any trail or terrain.

Wheels & Tires — The Perfect Stance with Purpose

Every Bronco deserves the right shoes, and this one wears them proudly. We went with KMC Tank Beadlock 17x9 -12mm wheels wrapped in Nitto Ridge Grappler 38x12.5R17 tires — the perfect balance of off-road traction, aggressive street presence, and durability for any terrain.

These 38s don’t just complete the look — they redefine it. The increased footprint provides unmatched grip and stability on loose rock, sand, and mud while maintaining a surprisingly smooth ride on pavement. But running tires of this size takes more than just clearance — it takes a drivetrain built to handle it.

Wrap — The Finishing Touch

To bring it all together visually, the wrap was designed by Pureblind and installed by HM Designs. The colorway and graphics tie the entire build’s theme together — rugged, refined, and ready for the spotlight.

Behind the Build: The Grind, The Grit, and The Glory

Every great build has a story — and this one’s written in long nights, tight deadlines, and relentless determination. When we got the news in September that our Bronco was officially selected as one of the ten finalists for the SEMA 2025 TORA Trail Showcase, everything shifted. The excitement was real, but so was the weight of the challenge. What started as a passion project quickly became an all-out sprint to meet one of the toughest deadlines we’ve ever faced.

What makes this story even more special is that it wasn’t done by a big crew or a massive shop. This entire build was brought to life by just two of us — a small team juggling late nights in the shop with full workdays running a busy business front. Every hour mattered. Every setback meant another night turning wrenches instead of turning in early. We had to balance customer commitments, daily operations, and the growing demands of a SEMA-level build all at once.

There were moments where it felt impossible. Parts arrived late, timelines got tighter, and fatigue started to creep in — but quitting was never an option. We kept pushing, problem-solving, and finding ways to make it happen. Piece by piece, the Bronco began to transform, and with each milestone, that exhaustion turned into motivation.

Some of the most rewarding moments came from the custom work — the things that weren’t in any instruction manual. Our last minute rear cargo build-out idea actually became one of our favorite parts of the project. The custom sliding shelf for the Iceco IPT20 fridge and integrated storage system were built to make real adventures more functional — not just look good for the show floor.

Then there’s the lighting — our 11-pod Diode Dynamics SSC2.0 Max Power Crosslink system, mounted into the TrailRax roof rack, was one of those “let’s push it further” moments. The sheer output and precision of that setup turned the Bronco into a rolling light cannon. Add in the custom gullwing rock lights on a pressure switch and the cargo lighting system, and suddenly the smallest details started making the biggest difference.

To round it all out, our Apex Designs Compact Reel System (CRS) paired with the ARB twin compressor and Adventure Labs roll bar mount became another functional masterpiece — the kind of setup that makes this Bronco trail-ready at a moment’s notice.

And now, as November 4th approaches and the big show finally begins, we can take a step back and know — every late night, every challenge, every ounce of effort was worth it. Seeing our Bronco lined up among the best of the best at SEMA 2025 isn’t just an achievement; it’s the payoff for months of hard work, grit, and belief in what two people can accomplish when they refuse to give up.

We don’t do this for the recognition. We’re not trying to be the loudest or flashiest in the room. But we are damn proud of what we’ve built — proud of the work, the effort, and the heart that went into every single detail.

At the end of the day, this Bronco isn’t just a showpiece. It’s proof that with passion, perseverance, and a couple of people crazy enough to chase a dream, you can build something truly unforgettable.

Giving Thanks — The Team Behind the Build

A project like this doesn’t come together alone. Behind every weld, bolt, and late night in the shop was a network of incredible partners who believed in our vision and helped us turn it into reality. From providing top-tier components to offering support, advice, and trust along the way — each one played a crucial role in bringing this Bronco to life.

This build represents more than just our hard work; it’s the result of collaboration, passion, and a shared commitment to excellence. We’re endlessly grateful for the companies that stood beside us through this process, supplying the innovation, craftsmanship, and reliability that made this project possible.

To our partners — thank you for being part of something truly special.

Our Deepest Thanks To:

• Ford Performance / Racing — for engineering the power, gearing, and reliability that drive this Bronco forward.

• Diode Dynamics — for lighting the way, literally, with world-class illumination and control.

• Anderson Composites — for bringing bold design and carbon craftsmanship to the forefront.

• DV8 Offroad — for armor, accessories, and functional design that tie strength and style together.

• Holley Performance — for providing performance innovation that keeps everything running at its best.

• RCI Metal Works — for bulletproof underbody protection that lets us tackle anything in our path.

• Icon Vehicle Dynamics — for creating the suspension foundation that makes this build unstoppable.

• TrailRax — for supporting our lighting system, storage, and adventure-driven functionality up top.

• Clazzio Leather — for delivering interior craftsmanship that’s as refined as it is rugged.

• Adams Driveshafts — for building the custom driveshaft that holds this powertrain together under pressure.

• Roam Adventure Co. — for providing dependable and functional storage solutions that complete our overland setup.

• Wheel Pros — for giving us the perfect platform to put power to the ground with strength and style.

This Bronco is more than a build — it’s a collaboration, a labor of love, and a testament to what’s possible when great minds and passionate creators come together.
From our two-man team to every partner who contributed — thank you for helping us build something nobody expected.

Derrick @ HSO