|
|
Its top and bottom air breather... Its top and bottom air breather plates are billet, and custom-machined to sit as low as possible for hood clearance while still drawing a deep breath. Even the K&N filter is custom-sized at 2.5 inches (K&N's production oval filter elements are either 2 or 3 inches high.) It's all about attention to detail. The point here is that much thought, engineering experience, and expertise have gone into these engines and engine/tranny packages, a statement backed up by the 2 year/24,000 mile warranty. "We actually perform oil consumption testing, transmission durability testing, and more on our packages," Todd explained. Time spent in one of Roush's powertrain-development cars, Bob Corn's '63 Galaxie XL ragtop, wowed us not just with king-of-the-hill power and instantaneous torque, but also with the refinement and utter driveability of its powertrain. It's the sort of musclecar that could comfortably be driven daily because it is simultaneously potent and well-mannered. And that modern driveability is a primary focus of this whole package idea. If this sounds interesting, our photos and captions will tell more of the story, but your best bet is to call the folks at Roush Performance and discuss the specifics of your project or wish list. Odds are they'll have something you can plug in and play with--and live with every day.
 Each crate engine is assembled;...  Each crate engine is assembled; start to finish, by an experienced Roush Performance builder. In the foreground is a 302-based powerplant nearing completion, while a 351 block stands waiting just behind.  Proven H-beam rods, forged...  Proven H-beam rods, forged pistons, and CNC-ported aluminum heads are standard throughout the crate engine lineup, whether small-block, FE, or 385-series. Right now, about 35 to 40 engines per month are crafted in these assembly stations that are well equipped, brightly lit, and cleaner than my kitchen. A lot cleaner, in fact.  We mentioned that as many...  We mentioned that as many as six different FEAD assemblies may be available for any given engine. One such option is Billet Specialties' Tru Trac serpentine setup, carved from large chunks of 6061-T6 aluminum.  Roush being Roush, the company...  Roush being Roush, the company has a stereolithography apparatus (SLA) to produce 3D prototypes directly from a CAD model. Seen here in yellow resin is a prototype bottom-plenum manifold for the FE eight-stack injector setup.  Here's a production, as-cast...  Here's a production, as-cast version of that manifold awaiting its turn on one of Roush's collection of CNC machines.  Many components, such as these...  Many components, such as these FE timing-chain covers, are custom-cast to Roush specifications. But any and all necessary machining is done in-house in order to maintain quality and consistency.  Every Roush crate engine gets...  Every Roush crate engine gets run-in and tested in one of the company's various dyno cells. Note the compact front dress (FEAD) on this small-block. It was originally created for the tight engine compartment orientation of the Superformance and Backdraft GT40 replicas, and is now popular in street rods wanting A/C.  By now, many of you are no...  By now, many of you are no doubt wondering how Roush bolts the modular-engine-pattern 4R70W up behind an FE. The answer is: "with a lot of modification." First, some old bolt holes are filled, then new chunks of aluminum are welded in place, and new holes drilled in the proper orientation. Obviously, this one isn't yet finished.  Here, the same unfinished...  Here, the same unfinished 4R70W case set on an FE block illustrates how the tranny must be clocked roughly 6 degrees off horizontal for proper starter orientation. The modular three-bolt starter is retained. This clocking eliminates the need for a spacer plate, allowing standard converters and flywheels to be used (not the case with spacer plates.)  The final piece of the puzzle...  The final piece of the puzzle in the FE/4R70W marriage is this engine rear cover plate, manufactured by Roush, with an FE bolt pattern and modular starter port. Incidentally, the flywheel used on the FE/4R70W application is a neutral-balance 184-tooth part from the 385-series big-block. The World's Nicest R&D Mule The whole idea of the Roush combos is to provide kit builders, hot rodders, and classic Ford owners a means of buying a powertrain that fits the first time, needs no further tuning or tweaking, and is powerful, tough, and utterly driveable and reliable, right out of the crate. Roush chose to put the theory into practice on this Galaxie. We drove this black classic, and can report that it personifies the "Velvet Brute" tagline that Ford once used to describe the full-size R-code cars. It idles in Drive with just the right amount of bumpstick attitude, but at a ridiculously low and even rpm, and then responds as you might expect 575 lb-ft of torque to respond: with grin-inducing alacrity and the squeal of overwhelmed rear tires. The transmission shifts according to throttle input; gently and early when demand is light, and firmly, but never harshly, when the right foot gets anxious. This XL has racked up plenty of development miles, and Bob Corn reports that it returns a frugal 15 highway mpg thanks, in part, to its overdrive automatic allowing a peaceful 2,300 rpm at 70 mph. The Galaxie was the first of the Roush powertrain project cars, and behind the mighty FE it has a 4R100, a stout but physically imposing truck trans. The effort, and clearancing, involved in fitting it into even something as large as the Galaxie was part of the reason why the much smaller 4R70W has since become the transmission of choice--with suitable internal, external, and programming upgrades, of course.  A black 1963 Galaxie 500 XL...  A black 1963 Galaxie 500 XL convertible with period Cragar rims makes a nice platform to introduce folks to the idea of packaged and matched engine/trans combos from Roush Performance. Originally a 352 car, this XL now packs much, much more.  It may be carbureted, but...  It may be carbureted, but a modern throttle position sensor sends its data to the transmission's electronic control module. The electronic control of modern transmissions means shift characteristics can be tailored and programmed to an owner's particular needs or wants.  The Galaxie now seems much...  The Galaxie now seems much smaller, thanks to the thrust of a 511-inch FE, based on a Shelby big-bore aluminum block, and rated at 525 hp. This is an example of Roush's mildest "SR" series architecture, having a dual-plane intake, and a relatively calm cam profile. A more aggressive carbureted version, along with central-throttle-body-injected, and individual-stack, port-injected (TWM) variants are also available.
|