From Desert Wreck to Buffalo Brown Masterpiece

Some vehicles arrive needing care; Rufus arrived on the edge of ruin. Imported from Saudi Arabia as a “restored” truck, it hid its secrets under a thin skin of paint—rotted panels welded over rust, a frame warped and scarred, mechanicals shattered, and desert mud baked into every seam. The axles groaned, the drivetrain was barely holding together, and corrosion had consumed the body from the inside out. What rolled into our workshop was no survivor; it was a casualty of decades of brutal off-road punishment, more scrap than Land Cruiser.

Forged Anew, Better Than New

Yet from that wreckage, something extraordinary emerged. We stripped Rufus down to bare steel, cutting away years of damage and decay, and rebuilt it bolt by bolt. Every surface was re-welded, every component renewed, and the 2F engine given a complete rebirth with machining, fresh internals, and a rebuilt carburetor. Suspension, axles, steering, and electrics were all redone with obsessive precision, while the cabin was carefully re-trimmed to blend authenticity with comfort. More than 4,500 hours later, Rufus reemerged—its skin gleaming in custom Buffalo Brown, accented with a white roof and silver bumpers. What was once a broken desert relic is now a timeless FJ40, resurrected stronger, cleaner, and better than it ever was new.

Highlights of the build:

  • Full frame-off, nut-and-bolt restoration spanning over 3,000 man hours

  • Custom Buffalo Brown paintwork with white roof, silver bumpers, and fully refinished body

  • 2F engine rebuilt from the block up – machined surfaces, honed cylinders, new pistons, rings, and bearings

  • Reconditioned cylinder head with fresh valves, guides, and seats

  • Rebuilt carburetor restored and tuned with electric fuel pump

  • Complete gasket and seal replacement throughout engine and drivetrain

  • Transmission and transfer case rebuilt, resealed, calibrated, and tested

  • Power steering box and pump overhauled, center arm and tie rods renewed

  • Front and rear axles rebuilt with new gears, bearings, seals, and hardware

  • Brake system fully overhauled with new booster, master cylinder, lines, and shoes

  • Aluminum radiator with electric fan installed

  • Old Man Emu suspension system with new shocks, leaf springs, and bushings

  • Frame blasted, straightened, and refinished against future corrosion

  • After-market alloy OEM-style 16” steel wheels in medium gray with chrome hubcaps

  • BFGoodrich All-Terrain tires fitted for capability and stance

  • Custom roll bar fabricated and powder coated with period-correct mounting

  • Full rewire with new harness, fuses, and modern relays

  • Dakota Digital instrument cluster calibrated for accuracy

  • LED lighting upgrade with OEM-style headlamps, signals, and rear lamps

  • Air conditioning and climate control system discreetly integrated for modern comfort

  • Finishing upgrades – mirrors, visors, and custom speaker panels

  • Restored interior with new white headliner, brown door cards, and Vintage floor mats

  • Seats rebuilt and reupholstered in distressed dark brown synthetic leather

  • Dash fully trimmed in new leather and switches renewed

  • Steering wheel wrapped in full grain leather

  • Air compressor with tank installed

  • Bluetooth audio system hidden with front and rear speakers

  • Backup camera integrated into the rearview mirror for modern safety

  • Restored shifter knobs, ashtray, dome lights, and window cranks with OEM-correct parts

  • Fuel system refreshed with new tank, lines, pump, and sender calibration

  • Exhaust system rebuilt and wrapped, tuned for correct tone and clearance

  • Every bolt cadmium or zinc-plated, every seal renewed, every detail restored

Cart (0)