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  • #4813
    V8 Staff
    Keymaster

    HI-RES LINK: http://v8tvshow.com/BOSS302.0/hi-res/V8TV_BOSS302L.jpg

    We are have started another cool project in the V8 Speed & Resto Shop (AKA V8TV) – The BOSS 302.0!

    This 1969 Mustang was literally a barn find and will be going through a complete transformation in our shop with some high-tech parts designed to make this a comfortable street cruiser that will also perform on an autocross or road course.

    The body shell will remain stock appearing, except for the addition of some carbon fiber body pieces from Anvil Auto. The Steinhauser Design rendering illustrates the clean appearance with the Anvil carbon fiber hood, bumpers, rear deck, quarter extensions, and dash face. Also visible are the Forgeline wheels and big brakes.

    Under the hood is a 5.0 Coyote engine and a manual transmission. The suspension is all from Detroit Speed, utilizing their new Mustang AlumaFrame and Mustang Quadra Link in the rear.

    We will be posting pictures and videos of the build of this car in this thread, and as always, feedback is appreciated!

    Check out:
    V8 Radio Podcast: https://www.v8radio.com
    V8TV YouTube Channel: https://www.youtube.com/user/V8TV

    #4814
    V8 Staff
    Keymaster

    Here’s what we’re starting with:

    It’s a pretty clean AZ car.

    Here is proof that this car came out of a barn!

    During the disassembly process, it appeared that we had a fairly clean car to start with.

    Check out:
    V8 Radio Podcast: https://www.v8radio.com
    V8TV YouTube Channel: https://www.youtube.com/user/V8TV

    #4815
    V8 Staff
    Keymaster

    The floor had some surface rust and the footwells appeared to be soft.

    Some grinding here and there revealed ugliness in the doors.

    And the driver side quarter panel was a victim to some previous repairs.

    Check out:
    V8 Radio Podcast: https://www.v8radio.com
    V8TV YouTube Channel: https://www.youtube.com/user/V8TV

    #4816
    V8 Staff
    Keymaster

    We trimmed the majority of the damage quarter panel skin, leaving the original edges and creases in place so that we could accomplish two things. First of all, this will allow the media blaster better access to the inner structure of the car. Second, it retains the alignment points for when we go to install the new quarter panel. When that time comes, we will install the deck lid, quarter extensions, and door before trimming the remaining edges of the original quarter panel. This will allow us to align the new panel to those pieces properly.

    We took a few minutes to make a closeout panel for the old heater box because we will be installing a Vintage Air AC system.

    Next up, the media blaster!

    Check out:
    V8 Radio Podcast: https://www.v8radio.com
    V8TV YouTube Channel: https://www.youtube.com/user/V8TV

    #4817
    V8 Staff
    Keymaster

    The BOSS 302.0 survived its visit to the media blaster with minimal surprises.

    The blaster left a few pieces of duct tape on the car to use as guides to illustrate how much filler was on the car in various places. The tail pan was toast, and the passenger quarter was pretty wrinkly from crash damage.

    It’s kind of hard to tell in this pic, but the passenger quarter was pushed in about 1/2″ and had been pulled before.

    Other than the quarter panel damage, the blasting process did not reveal any new surprises.

    After the initial inspection, the crew spun the car on the Autowirler while blowing it out to free any loose blasting media. THen they attacked the car with an 80-grit DA sander to knock off the rough media blast texture, then scrubbed it with Scotchbrite pads and wax & grease remover before a final blow-down and BASF EP760 Epoxy Primer.

    You’ll note that the panels targeted for removal were not primed completely to save on materials.

    Overall, the shell is very clean, and will provide a great foundation from which the BOSS 302.0 will evolve!

    Check out:
    V8 Radio Podcast: https://www.v8radio.com
    V8TV YouTube Channel: https://www.youtube.com/user/V8TV

    #4818
    V8 Staff
    Keymaster

    The BOSS 302.0 will be running the Ford Racing 5.0 Coyote engine, and the package comes with a controller and harness to make it all function.

    The harness resembles most EFI harnesses, with a couple extra connectors for the 4 cam position sensors. The Coyote makes 412 HP and weighs 440 lbs, and all 4 cams are variable. Pretty cool stuff.

    The ECM is a OE grade unit, and is OK to mount under the hood or even in a fenderwell. The manual explains the options.

    We like the supplied power center, which houses the relays and provides LED indicators for quick visual verification of successful operation of each circuit. We like to put these in the glove box so you can see what’s up at a glance.

    Check out:
    V8 Radio Podcast: https://www.v8radio.com
    V8TV YouTube Channel: https://www.youtube.com/user/V8TV

    #4819
    V8 Staff
    Keymaster

    These engines do not have provisions for power steering pumps, as the new Ford cars they power have electric steering.

    Here you can see the Vintage Air Frontrunner serpantine belt and A/C system for the 5.0. The Vintage Air unit adds the pump as well as the A/C compressor in a tight package.

    The 5.0 is an aluminum engine, and although we love the look of the raw cast block, heads, and bracketry, we hate how the aluminum oxidizes and turns ugly over time. So we’ve been coating engines with Eastwood’s Ceramic Engine Paint in Aluminum Silver. We shot a test part with this stuff and cooked it to 500 degrees in our oven without any hint of color change or blistering, and it resists solvents. So now aluminum parts stay looking like aluminum thanks to the “nano ceramic technology”. That’s OK, I don’t know what it means either.

    Here’s a sneeky-peeky of how the 5.0 fits in the engine bay with the Detroit Speed Aluma-Frame underneath.

    Check out:
    V8 Radio Podcast: https://www.v8radio.com
    V8TV YouTube Channel: https://www.youtube.com/user/V8TV

    #4820
    V8 Staff
    Keymaster

    Here’s the intro video on the BOSS 302.0.

    In this video, we extract the car from the barn, and go over the plan and design concepts for the car.

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    Click to

    Here’s the video install of the Detroit Speed Aluma-Frame and front suspension system. Some of the holes are a little tricky to drill, but overall, the install went smoothly. Can’t wait to drive this one!

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    Here’s the first part of the Detroit Speed QUADRALink install, this is the deep tub and brackets that go on the car’s body.

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    We’re installing a trick suspension system based around the Detroit Speed AlumaFrame subframe. The AlumaFrame is a cast-aluminum cradle that bolts to the Mustang’s front rails and provides suspension mounting points for the Detroit Speed tubular suspension system.

    The AlumaFrame consists of a variety of parts that all work together, the largest being the frame itself. Other parts include the upper control arm mounts and the upper coil-over shock brackets. There are shims and steel plates which are used for mounting the frame.

    Holes are drilled in the original rails to allow the AlumaFrame to attach.

    Check out:
    V8 Radio Podcast: https://www.v8radio.com
    V8TV YouTube Channel: https://www.youtube.com/user/V8TV

    #4821
    V8 Staff
    Keymaster

    The frame is bolted in place, and care is taken to ensure it goes in squarely.

    Inserts are welded into the frame rails to add strength and to prevent the AlumaFrame mounting from crushing the stamped rails.

    Lower control arm travel limiters and bump stops are welded to the outsides of the frame rails.

    The system uses tubular upper and lower control arms rather than the stamped steel units originally used on the Mustang. The lower arms are true “A” arms rather than the strut-rod design, which allow for more precise articulation of the suspension system. It also uses modern spindles, coil-over springs & shocks, articulated sway bar ends, and a quick ratio rack and pinion steering system.

    Check out:
    V8 Radio Podcast: https://www.v8radio.com
    V8TV YouTube Channel: https://www.youtube.com/user/V8TV

    #4822
    V8 Staff
    Keymaster

    Detroit Speed uses a system of star-shaped adjusters to make alignment changes without the need for additional shims or washers.

    We took a few minutes to drop our 5.0 engine into place to assess the fit and the overall “lay of the land.”

    Once the front was installed, the crew moved to the rear of the car to start installing the Detroit Speed QUADRAlink parts.

    http://www.v8tvshow.com/BOSS302.0/slides/69_Boss302.0_08.28.12_86.JPG%5B/img

    Check out:
    V8 Radio Podcast: https://www.v8radio.com
    V8TV YouTube Channel: https://www.youtube.com/user/V8TV

    #4823
    V8 Staff
    Keymaster

    The QUADRAlink brackets require additional clearance in the trunk floor area, and Detroit Speed provides pre-formed panels to make it all fit. Also shown are the panhard bar mounts and rear axle control arm mounts.

    The trunk area was braced, as the wheel tubs, floor, quarters, and eventually the tail pan will all be replaced.

    Check out:
    V8 Radio Podcast: https://www.v8radio.com
    V8TV YouTube Channel: https://www.youtube.com/user/V8TV

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