Sometimes, even the best off-road adventures don’t go according to plan.
At Westcott Designs™, we spend a lot of time behind the wheel testing new products, evaluating vehicle performance, and pushing our builds to deliver the quality and functionality our customers expect.
But during a recent outing in our 2025 Ford F-150 Raptor, things took an unexpected turn.
One rock, one split-second mistake, and suddenly our nearly new Raptor was declared a total loss.
The surprising part? Looking at the truck, you might not even realize how serious the damage was.
Here’s what happened, why the insurance company totaled the truck, and why we’re rebuilding it instead of walking away.
Watch: OH NO! I Totaled Our New 2025 Raptor
Watch Jeff Explain What Happened to the 2025 Ford Raptor
In this video, Jeff from Westcott Designs™ walks through the damage, explains the decision to replace the frame, and shares what’s next for the Raptor build.
How Our 2025 Ford Raptor Accident Happened
We were out testing components on our Ford Raptor, including some of our own Westcott Designs™ products and accessories from other manufacturers.
Testing is an important part of our development process. We want to understand how products fit, function, and perform on the vehicles they’re designed for.
Jeff and his wife were driving when a momentary distraction changed everything.
While Jeff was looking down at the dashboard navigation system, the truck rounded a bend and encountered a large rock.
They were traveling at approximately 65 mph.
The front wheel struck the rock, causing the truck to move sideways. As the vehicle shifted, the rock made additional contact along the side of the Raptor.
The impact damaged several areas of the truck, including the wheel area, side step, door, and a small section of the bed.
Fortunately, the incident wasn’t worse.
But what initially appeared to be relatively limited exterior damage turned out to be something much more serious.
The Hidden Damage That Totaled Our Ford Raptor
At first glance, the Raptor didn’t look like a vehicle that would be considered a total loss.
There was visible damage, but much of the truck still appeared intact.
The real problem was underneath.
A Bent Frame Changed Everything
The impact had damaged the Raptor’s frame.
Jeff points out an area where the frame was visibly bent, with cracked paint indicating the extent of the deformation.
The front wheel had also been pushed backward from its normal position.
Frame damage is particularly serious because the frame serves as the structural foundation of a body-on-frame truck like the Ford F-150 Raptor.
It supports major vehicle components and plays an essential role in maintaining proper suspension geometry, alignment, and structural integrity.
Even when exterior damage appears manageable, frame deformation can make repairs significantly more complicated.
Additional Damage Around the Truck
The accident also caused damage to several exterior components.
The side step was bent toward the rear, the door sustained damage, and the rock made light contact with the bed.
At the front of the vehicle, composite body components were broken, and the lower portion of a fender flare was cracked.
While these components can potentially be repaired or replaced, the frame damage became the deciding factor in the truck’s future.
The insurance company declared our 2025 Ford Raptor a total loss.
Why Would an Insurance Company Total a Truck That Looks Repairable?
It’s a question many vehicle owners ask after an accident.
How can a truck that still looks relatively intact be considered totaled?
The answer often comes down to the cost and complexity of repairs compared with the vehicle’s value and the applicable insurance total-loss criteria.
A vehicle doesn’t necessarily have to be completely destroyed to be declared a total loss.
Structural damage, especially damage involving the frame, can require extensive labor, specialized equipment, and significant component replacement.
In our case, the frame damage was serious enough that the insurance company totaled the Raptor.
But we weren’t ready to give up on the truck.
Our Decision: Buy Back the Raptor and Replace the Frame
Rather than letting the Raptor go, we decided to purchase it back after the insurance settlement.
We had already invested considerable time developing, installing, and testing products on this truck.
It was an important part of our ongoing Ford Raptor product development program.
More importantly, we believed there was a path to rebuilding it properly.
Why We Chose a New Ford Frame
Before making the decision, we had the truck inspected by Al’s Frame Shop.
After evaluating the damage, the shop determined that the existing frame could not be repaired appropriately.
Instead of attempting to straighten the damaged section, we decided to replace the frame entirely.
We ordered a brand-new replacement frame from Ford and arranged for the truck to be taken to Al’s Frame Shop.
The plan was to transfer the necessary components onto the new frame and rebuild the Raptor.
It’s a significant undertaking, but for us, doing the job correctly matters more than taking shortcuts.
The rebuilt truck will still require appropriate inspections, mechanical checks, and alignment verification before returning to service.
How Did Our Westcott Designs™ Front Bumper Hold Up?
One of the most interesting observations following the accident was the condition of our Westcott Designs™ front bumper.
Despite the impact and surrounding vehicle damage, Jeff reported that the bumper itself did not bend.
That’s an encouraging observation for a product we’ve spent time developing.
However, it’s important to distinguish the bumper’s observed condition in this particular incident from any broader claims about crash protection or structural performance.
The bumper was one component of a vehicle that experienced significant damage elsewhere.
Still, seeing the bumper remain visibly intact gave us another opportunity to examine the product following real-world use.
A Look at the Westcott Designs™ Ford Raptor Accessories
Although the accident interrupted our testing schedule, we’ve continued making progress on our growing lineup of Ford Raptor aftermarket accessories.
During the video, Jeff highlights several products and developments that are part of the build.
Ford Raptor Front Bumper
Our Westcott Designs™ front bumper is designed around the Raptor platform, with attention to vehicle-specific fitment and accessory integration.
The featured truck also incorporates mounting provisions for a high-mount intercooler setup.
As Jeff explains, portions of the intercooler installation connect to mounts integrated into the upper section of the bumper.
Ford Raptor Rock Sliders
We’ve also developed a new set of Ford Raptor rock sliders.
Rock sliders are an important consideration for owners who take their trucks onto rocky or technical trails.
Unlike conventional side steps, properly designed rock sliders focus on helping protect vulnerable lower body areas from contact with obstacles.
Our Raptor slider development expands the available options for owners looking to build a more trail-ready truck.
Ford Raptor Rear Bumper
A rear bumper is another important component of a complete off-road build.
Our rear bumper development is part of our effort to offer a more comprehensive range of Raptor accessories.
Ford Raptor Bed Rack and Chase Rack
For owners who want additional equipment mounting options, bed racks and chase racks can provide practical solutions.
Jeff confirms that our rack development has progressed alongside the other Raptor components.
These accessories can be an important part of configuring a truck for off-road recreation and adventure.
Ford Raptor Ditch Light Mounts
Our new ditch light mounting solutions are also part of the Raptor product lineup.
Auxiliary lighting is popular among off-road enthusiasts who need additional illumination for appropriate nighttime trail use.
Thoughtful mounting solutions help integrate lighting equipment into the vehicle without compromising its overall appearance.
Product availability, compatibility, and configurations should be confirmed on the Westcott Designs™ website.
Additional Upgrades on Our 2025 Ford Raptor
Beyond the Westcott Designs™ accessories, our Raptor featured several other modifications.
Brembo Brake Upgrade
The truck was equipped with a larger Brembo brake setup.
Braking system upgrades require careful consideration of component compatibility, wheel clearance, and proper installation.
High-Mount Intercooler
Our Raptor also featured a high-mount intercooler configuration with a visible blow-off valve.
During the teardown process, some components were temporarily secured after their normal mounting connections were removed.
As Jeff explains in the video, we removed as many accessories as practical before the frame replacement to help reduce the time and cost associated with transferring components.
Once the new frame is installed, these systems will need to be properly reassembled and inspected.
What’s Next for Our 2025 Ford Raptor Build?
The accident certainly wasn’t part of the plan.
But it doesn’t mean the end of this Raptor.
Our next step is to complete the frame replacement and begin putting the truck back together.
From there, we’ll reinstall the necessary components, inspect the vehicle, and prepare it for future use once the rebuild has been properly completed.
We’re also looking forward to continuing development on our growing lineup of Raptor accessories.
At the time of the video, Jeff anticipated getting the truck back from the frame shop within approximately two weeks, although the actual rebuild timeline depends on parts, labor, and inspections.
We’ll continue sharing updates as the project progresses.
Frequently Asked Questions About Our Ford Raptor Accident and Rebuild
Why was the Westcott Designs™ 2025 Ford Raptor totaled?
The truck was declared a total loss after striking a large rock, which caused significant frame damage. Although the exterior damage appeared relatively limited, the frame was bent and the front wheel had been pushed backward from its normal position.
Can a totaled Ford Raptor be rebuilt?
A totaled Ford Raptor may be rebuildable depending on the damage, repair feasibility, applicable laws, and required inspections. In this case, Westcott Designs™ purchased the truck back and ordered a replacement frame from Ford. The vehicle’s future registration and roadworthiness depend on successful repairs and applicable requirements.
Why replace the frame instead of straightening it?
After inspecting the damage, Al’s Frame Shop determined that the existing frame could not be appropriately repaired. Westcott Designs™ therefore chose to replace it with a new Ford frame rather than attempt to straighten the damaged structure.
Did the Westcott Designs™ front bumper survive the accident?
According to Jeff’s inspection in the video, the Westcott Designs™ front bumper did not bend during the incident. That observation applies to this specific accident and is not a substitute for controlled safety or crash testing.
What aftermarket accessories were installed on the Raptor?
The truck featured a Westcott Designs™ front bumper, a larger Brembo brake setup, and a high-mount intercooler configuration. Jeff also discussed the company’s development of rock sliders, rear bumpers, bed racks, chase racks, and ditch light mounts for the Raptor platform.
Will Westcott Designs™ continue testing products on this Raptor?
That’s the plan. Once the replacement frame is installed and the truck is properly rebuilt and inspected, Westcott Designs™ intends to resume its Raptor development and testing activities.
The Raptor Build Isn’t Over Yet
One thing we’ve learned from years of building and working on off-road vehicles is that things don’t always go as planned.
Sometimes, a project takes an unexpected turn.
In this case, our 2025 Ford Raptor suffered enough damage to be declared a total loss.
But rather than closing the chapter, we’ve decided to rebuild it.
We’re looking forward to getting the new frame installed, putting our accessories back on, and continuing the development work that makes Westcott Designs™ what it is.
This Raptor isn’t finished. We’re just getting started on the next chapter.
Want to follow the rebuild and see our latest Ford Raptor products?
Explore Westcott Designs™ Off-Road Accessories
And subscribe to the Westcott Designs™ YouTube channel for upcoming Raptor rebuild updates, new product releases, installation walkthroughs, and behind-the-scenes testing.