KJ Jonesx
September 26, 2011
Photos By: KJ Jones

As you know, we've been on the throttle pretty hard since the Mar. '10 issue, bringing you the latest in cutting-edge tech for the newest Mustangs. We hope you're enjoying our tests and their results. Thus far we've already learned quite a bit about the new 5.0 powerplant's performance potential. In all honesty, it doesn't seem as though we're closing in on any limit yet.

There's no way we'd ever intentionally try to make Coyote-powered 'Stangs seem passe. However, our commitment to bringing you the latest in innovative concepts has forced us to step up our already-solid 5.0 game by incorporating '12 Boss 302 Ponies in our tech mix.

Bosses are driven by the higher-output (444 crankshaft horsepower with 380 lb-ft of torque) RoadRunner version of the 32-valve 5.0. They also feature a gang of handling improvements, Recaro seats (optional), exclusive appearance treatments, and a power-boosting TracKey (a special key that activates Ford's TracMode PCM calibration for track use) that makes the street-legal race cars a bit more exclusive than their GT brothers.

Shortly after Boss 302s made their official debut, we embarked on a mission to find out the impact that adding a power adder has on the already-hot RoadRunner engine. To date, we've loaded Bosses with twin-screw superchargers ("Kenne Boss," Oct. '11, p. 52), an assortment of basic bolt-ons, and, of course, the reliable power in a bottle that is nitrous oxide ("Boss Flog," p. 98).

While the results of our efforts have been outstanding, we know there's still a lot more Boss power to discover. Evolution Performance of Aston, Pennsylvania, is a hard-core Mustang crew that shares our interest in uncovering this power, so our curiousity was immediate when Fred "What Do You Think About This Idea" Cook proposed the supercharger experiment we're detailing in this report.

"To go all out, you don't pussyfoot--you just do it. That's how it is," says Fred. In this case, going all out involves strapping ProCharger's race-specific F-1C on Rick Wilson's bone-stock, Yellow Blaze Boss (number 468) to see if the union can make the horses run wild on the chassis dyno.

Yes, we're putting a different spin, if you will, on ramming gobs of intercooled air into a '12 RoadRunner 5.0 engine. The F-1C is a centrifugal blower that's capable of producing more than 35 psi of boost. Of course, we won't use that much forced air on our tester, but we do plan on experimenting with a couple of pulleys to determine what it takes to make really big steam with a predominately stock Boss 302. We say predominately OEM, because our project includes adding a full exhaust from American Racing Headers.

If you haven't put two-and-two together yet, this effort is another part of our blower bonanza at Evolution--a second project that your Tech Editor and Evo's Chuck "No Smoke" Wrzesniewski handled in a whirlwind week of bolting boost onto Boss 302s.

It's important to understand that the process of installing any blower on a '12 Boss comes with unique nuances that make the job a bit more involved than it is on Coyote-powered, '11-'12 'Stangs. While there are many tasks that cross over (initial removal of pieces such as the front fascia, airbox, injectors, coolant tank, and such), reassembly on a Boss is not as textbook, as the tubing layout is slightly different. Also, Copperhead PCM logic for RoadRunners features many different protocols that must be manipulated by tuning specialists such as our friend Jon Lund (www.lundracing.com).

Making over-the-top power at the feet of one of these specialty 'Stangs is a total rush. Check out the photos and captions and see how we turned Rick's ride into the most formidable, street-driven Boss 302 to date.

On the Dyno

The F-1C ProCharger showed us it means business right away when we loaded our project Boss 302 on the Mustang chassis dyno at Evolution Performance.

Tunemaster Jon Lund actually used a brand-new tuning software that's in development for our effort. With Jon doing his thing with the 'Stang's PCM (changes for this effort included advancing the exhaust timing to improve scavenging efficiency), the blower sent horsepower beyond the 700 mark with a 5.00-inch pulley installed. That's insane power right out of the gate (given the large diameter of the wheel), and it gave us confidence that we were on track for (what we figured would easily be) 900 hp at the tires.

ProCharger's big centrifugal is a beast in the upper rpm range, which is where Boss 302s' RoadRunner powerplant is most content. As we anticipated, big steam with the F-1C comes on around 5,000 rpm with 5- and 4.5-inch pulleys, making the car docile and easily driven at low speed (with Jon's tuning), and equally controllable up top because the power increase is linear from 5,000 through the 7,500-rpm rev limit.

Off the dyno and on the street, when cruising on the highway at 60 mph and downshifting into Fifth gear, our newly boosted Boss hazed 20-inch Nitto drag radials through 100 mph.

It's clear that with a fuel system capable of supporting an effort like this (the stock unit was absolutely maxed out and air/fuel was "don't-try-this-at-home" lean on our glory pull), as well as a 4.25- or 4.00-inch blower pulley, a Boss 302 with an F-1C ProCharger can certainly get pretty close to putting down 1,000 horses at the feet. Of course, at that point, the durability of the engine's internals certainly will be a big concern. But pushing that proverbial envelope of high performance is what we're all about, and the unique, special Boss 302 is a fantastic platform for our attempts at pulling maximum horsepower from stock 'Stangs.

Thanks to Nelson Whitlock, Fred Cook, No-Smoke Chuck Wrzesniewski, and Kent Kiehl at Evolution Performance, and also tuning specialist Jon Lund, as they made these experiments possible. Rumor has it Evo is currently working on a fix for the shortcomings of the latest Mustangs' stock fuel system. Our plan is to stay on top of this development, and see how much additional power can be generated with Rick Wilson's Boss 302. Stay tunedà

Baseline 5-inch 4.5-inch Baseline vs. 5-inch
RPM PWR TQ PWR TQ PSI PWR TQ PSI PWR TQ PSI
2,500 142 292 n/a n/a n/a n/a n/a n/a n/a n/a n/a
2,600 150 296 n/a n/a n/a n/a n/a n/a n/a n/a n/a
2,700 158 301 n/a n/a n/a n/a n/a n/a n/a n/a n/a
2,800 165 305 n/a n/a n/a n/a n/a n/a n/a n/a n/a
2,900 173 308 n/a n/a n/a n/a n/a n/a n/a n/a n/a
3,000 180 309 226 387 2.9 268 438 4.3 88 129 1.4
3,100 185 309 234 390 3.1 276 445 4.4 91 136 1.3
3,200 192 310 246 396 3.4 286 451 4.6 94 141 1.2
3,300 199 312 259 404 3.6 295 459 4.8 96 147 1.2
3,400 205 313 272 411 3.8 312 470 5.1 107 157 1.3
3,500 212 314 283 416 4.1 329 482 5.3 117 168 1.2
3,600 220 316 297 425 4.3 346 493 5.6 126 177 1.3
3,700 227 318 311 434 4.5 364 505 5.9 137 187 1.4
3,800 234 320 327 443 4.7 383 516 6.3 149 196 1.6
3,900 242 321 342 452 5.0 401 528 6.6 159 207 1.6
4,000 250 323 358 461 5.2 420 539 6.9 170 216 1.7
4,100 257 325 374 470 5.4 438 549 7.2 181 224 1.8
4,200 264 326 392 481 5.6 457 559 7.6 193 233 2.0
4,300 271 327 409 490 5.9 475 568 7.9 204 241 2.0
4,400 279 329 426 499 6.2 493 576 8.3 214 247 2.1
4,500 286 329 442 506 6.5 511 584 8.7 225 255 2.2
4,600 292 329 457 513 6.7 529 591 9.1 237 262 2.4
4,700 297 329 472 519 7.0 547 598 9.5 250 269 2.5
4,800 304 329 486 523 7.3 564 605 9.8 260 276 2.5
4,900 310 329 501 529 7.5 583 612 10.2 273 283 2.7
5,000 316 329 517 534 7.8 601 619 10.6 285 290 2.8
5,100 322 328 535 542 8.1 621 627 10.9 299 299 2.8
5,200 328 328 553 549 8.4 641 634 11.3 313 306 2.9
5,300 334 327 571 556 8.7 661 642 11.7 327 315 3.0
5,400 339 327 587 562 .09 681 649 12.1 342 322 3.1
5,500 343 324 603 566 9.4 700 656 12.4 357 332 3.0
5,600 346 322 618 571 9.6 720 662 12.7 374 340 3.1
5,700 350 320 632 574 9.9 737 666 13.1 387 346 3.2
5,800 353 317 646 577 10.2 753 671 13.5 400 354 3.3
5,900 354 313 656 577 10.5 769 673 13.8 415 360 3.3
6,000 356 309 666 576 10.8 782 674 14.1 426 365 3.3
6,100 358 306 675 574 11.1 793 673 14.5 435 367 3.4
6,200 359 302 683 571 11.4 803 671 14.8 444 369 3.4
6,300 360 298 690 569 11.8 811 667 15.1 451 369 3.3
6,400 360 294 698 566 12.1 817 662 15.4 457 368 3.3
6,500 361 290 705 563 12.4 822 656 15.7 461 366 3.3
6,600 361 286 712 560 12.8 827 651 15.9 466 365 3.1
6,700 361 281 717 557 13.1 829 647 16.0 468 366 2.9
6,800 361 277 722 556 13.2 832 645 16.1 471 368 2.9
6,900 361 273 725 555 13.4 833 641 16.2 472 368 2.8
7,000 360 269 728 552 13.6 833 635 16.4 473 366 2.8
7,100 360 265 731 551 13.8 834 631 16.5 474 366 2.7

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