Inside a Frame-Off Restoration: What We Touch, Replace, and Reinvent
A true frame-off Bronco restoration is the gold standard in classic vehicle rebuilding—and at HighLine Classics, it’s our signature craft. This article walks you through every stage of our process, from the first bolt removed to the final road test. Along the way, you’ll see the dramatic before-and-after transformations that turn weathered legends into show-quality, daily-drivable classic Broncos.
Here’s what you’ll learn:
What “frame-off” really means and why it ensures unmatched quality and reliability.
Our step-by-step restoration process, with photo callouts at each stage.
How modern performance upgrades like the Coyote 5.0 V8 blend with timeless Bronco styling.
Customization and warranty details, so you know exactly what’s included.
Links to real builds, letting you explore finished projects for inspiration.
Through it all, you’ll understand why HighLine Classics’ process results in more than just a restored classic Ford Bronco—it delivers a brand-new driving experience wrapped in vintage steel.
The Complete Transformation Promise
At HighLine Classics, a frame-off restoration is exactly what it sounds like—every nut, bolt, and wire replaced, every surface refinished, every component re-engineered for decades of dependable driving. This isn’t just a facelift; it’s a rebirth. We strip each Bronco down to the bare frame, then meticulously rebuild it 100% in-house using all-new, Ford-licensed bodies, new Coyote 5.0 engines, modern drivetrains, and premium finishes.
The result? A brand-new Bronco wearing its original VIN, crafted to your exact specifications and capable of handling anything—from coastal cruising to backcountry trails.
Stage 1: Complete Disassembly
Every restoration begins with a complete teardown of an old Ford Bronco. The body is carefully lifted from the frame, and every single part—down to the smallest fastener—is removed.
By the time disassembly is complete, your classic Bronco is reduced to its frame. This is the only component that will be reused in the process. It’s the moment where “classic” meets “blank canvas.”
Before Photos: See the untouched classics as they arrive—rust, dents, and all.
Stage 2: Frame Restoration Foundation
The frame is the backbone of any classic Ford Bronco—and at HighLine Classics, it’s where your build earns its timeless beauty and future reliability.
Step-by-Step Process:
Inspection & Measurement – We check the frame for straightness, cracks, or hidden damage.
Media Blasting – Strips away decades of rust, paint, and grime, revealing clean, bare steel.
Repairs & Reinforcement – Any imperfect body mounts are removed and new ones are welded on and reinforced to factory or better-than-factory specs.
Powder Coating – A durable, corrosion-resistant finish that seals and protects for years to come.
This is also where we integrate modern performance upgrades—mounts for the Gen 4x Coyote 5.0 engine, upgraded suspension components, modern brake systems, and any custom modifications you’ve requested.
A restored frame doesn’t just look immaculate; it’s engineered to deliver the handling, safety, and performance expected from a modern vehicle.
Before/After Photos: See the dramatic transformation from pitted steel to gloss-black perfection.
Stage 3: Body Resurrection
A HighLine body restoration is an art form—over 400 hours of metalwork go into ensuring perfect panel fitment and show-quality lines.
We begin with a brand new Ford-licensed body. Every weld is dressed and smoothed, every gap adjusted to precise tolerances. Once the metalwork is flawless, we move into paint preparation: high-build primers, block sanding, and sealing to create a mirror-smooth base.
The paint process is multi-stage, using premium automotive finishes in your chosen color.
This stage ends with the body ready for assembly—gleaming, straight, and ready to meet its newly restored frame.
Before/After Photos: Watch the body go from weathered and worn to concours-level shine.
Stage 4: Modern Drivetrain Integration
Here’s where the heartbeat returns. We install a brand-new Gen 4x Ford Coyote 5.0 V8—paired with your choice of automatic or manual transmission—delivering modern horsepower with bulletproof reliability.
The drivetrain includes new axles, transfer case, driveshafts, and disc brakes, all engineered to work together seamlessly. Every component is installed with precision, ensuring proper alignment, smooth operation, and easy serviceability down the road.
The result: muscle-car acceleration, modern technology, highway comfort, and off-road confidence—all wrapped in classic Bronco style.
Before/After Photos: From empty engine bay to 460HP modern muscle.
Stage 5: Final Assembly & Testing
In the final stage, we reunite the body and frame, install every trim piece and the interior, and fine-tune every system. The custom Bronco is road-tested, adjusted, quality checked and detailed before delivery. You’ll receive a show-quality, daily-reliable classic—ready to put a smile on your face every time you turn the key.
Bronco Restoration FAQ
How long does a frame-off restoration take?
Most HighLine builds take 12-14 weeks, depending on customization. Each Bronco is built 100% in-house from the bare frame up, so timelines account for meticulous metalwork, body work, finishing features, drivetrain installation, and testing. We’ll provide you with a detailed build schedule at the start and keep you updated at every milestone.
What’s included?
A true frame-off at HighLine means every nut, bolt, and wire is new—plus a Ford-licensed all-metal body, new Gen 4x Coyote 5.0 engine, new transmission, modern axles, disc brakes, and custom finishes. We also install new glass, weatherstripping, wiring harness, suspension, and interior. The result is essentially a brand-new Bronco with vintage styling.
Do you use the original frame for an authentic restoration?
Yes. We provide the titled donor frame, or can restore your Bronco’s original frame to better-than-new condition, keeping the factory VIN for authenticity. The frame is media blasted, repaired if needed, powder-coated for rust-free durability, and updated with modern mounts for your chosen drivetrain and suspension upgrades. We also provide options for an aftermarket Kincer Freeway Chassis if you want a more modern rear suspension system. These frames lack the factory VIN number, but the body will still retain the factory VIN tag, and it will still be titled as a 1966-77 Ford Bronco.
Can I customize my build for a personal touch?
Absolutely. You choose all cosmetic enhancements from paint color and interior materials to wheel style, suspension setup, and performance upgrades. We’ll guide you through a design consultation to ensure your Bronco fits both your aesthetic and functional goals—whether that’s a daily driver, showpiece, or off-road machine.
Is there a warranty?
Every custom classic Ford Bronco build comes with a 1-year bumper-to-bumper warranty and a 2-year/24,000-mile powertrain warranty from Ford. This ensures peace of mind and coverage similar to buying a new vehicle. Our Broncos are built for daily reliability, so you can enjoy them without constant maintenance concerns.
What’s the total budget for the full frame off restoration process?
All Bronco builds start at $189k, but depending on your chosen upgrades, finishes, and accessories the final price may land in the low $200,000 range. The price reflects 100% in-house craftsmanship, premium materials, and the use of all-new components. We’re transparent with pricing, offer financing solutions, and provide a detailed proposal before work begins.
Your Dream Classic Ford Bronco Starts Here
A frame-off Bronco restoration isn’t just about bringing a vehicle back to life—it’s about building a machine that’s better than new, engineered for decades of adventure, and tailored entirely to you. At HighLine Classics, every project is a collaboration, every detail is intentional, and every finished Bronco is a legend reborn.
If you’re ready to take the first step toward owning a HighLine Bronco, we invite you to connect with us directly. You’ll work one-on-one with our founder, Josh Dougherty, to design and build a classic Bronco that fits your lifestyle, your vision, and your expectations for quality.
Your dream Bronco deserves more than a restoration—it deserves a HighLine transformation. Start Your Build Consultation today.