Horse Sense: In what has...
Horse Sense: In what has become a standard practice when I make my annual trip to the East Coast (for our coverage of the NMRA event at Atco Raceway in New Jersey), a tech project is included in the journey. For this year's exercise, an evaluation of basic bolt-ons for '05-'09 Mustang GTs, installation and dyno tests are being handled at Realspeed Automotive of Bohemia, New York; a hard-core Mustang center on Long Island that caters exclusively to all of the modern-day Pony platforms ('79-'93, '94-'98, '99-'04 and '05-'10).
Yes, the subject matter is territory that we've visited many times before with 5.0 Mustangs and their younger, modular-powered siblings. This exercise in installing and testing S197 bolt-ons covers the simple air-efficiency upgrades (cold-air intake, larger throttle-body, free-flow mufflers, and tuning) that we believe are excellent first-step performance modifications for '05-'10 'Stangs. However, in each instance we like to experiment with components that are made by different manufacturers, to see exactly how well certain parts work on a stock Pony, both individually and when combined with each other for evaluation as affordable, bolt-on performance packages for Three-Valve-powered, '05-present Mustang GTs.
We've doled out plenty of criticism about the poorly designed, super-restrictive, OEM air-intake systems that are trademarks on the modern-era (from 1986 to present) stock Mustangs that we've worked with, and explained how fresh outside airflow into a 'Stang's engine, or, more specifically, the lack thereof, hinders performance.
That's right. The '09 Mustang...
That's right. The '09 Mustang GT we're using for this bolt-on experiment is brand new! Jack Frost, sales manager at Sayville Ford, was kind enough to spot us the bone-stock 'Stang we're using for our test. The hopped-up Pony is headed back to the showroom floor (with the upgrades still intact) once we're finished with it, so make sure you say you want the "car that was used in the 5.0&SF tech article" when you call Jack about buying it.
Inefficiency doesn't stop at the engine. Exhaust gases that exit through factory mufflers are equally as detrimental to a Mustang's chassis-dyno (and more importantly, seat-of-the-pants) performance, as the aforementioned air-inlet passages are. Time has shown that installing bigger (larger diameter), non-restrictive pieces in both of these areas, is the best way to bring out more of a 'Stang's inherent rear-wheel horsepower. Also, through years of testing Mustangs, we've learned performance gains that result from bolting on the basics, can further be improved by using the chassis dyno and tuning software to recalibrate the PCM for an optimum air/fuel ratio.
The super-sized S197 parts for this test come to us courtesy of R2C Performance (cold-air system), Metco Performance (Shelby GT500 throttle body and spacer), Ford Racing Performance Parts (FR500CJ throttle body) and Kooks Custom Headers (axle-back exhaust). Realspeed Automotive's owner, Dan Carlson, and technicians Rob DeMartinis and Rodney Yu (the irony in the sight of Rodney, a Mustang tech, arriving at the shop in a full-on, tuner-style import ride was hilarious) spent a day installing and dyno-testing our upgrade package on a brand-new, '09 Mustang GT that was graciously provided by Jack Frost of Sayville Ford.
 Since Kooks Custom Headers...  Since Kooks Custom Headers is located less than 30 minutes from Realspeed, we're taking the efficient route (no shipping) and using Kooks' bolt-in, axle-back exhaust system for '05-'09 Mustangs with 4.6-liter Three-Valve engines (PN 6030; $750). The 2½-inch tubing and mufflers in this kit are completely stainless steel, and the freer-flowing cans will improve exhaust's exit and the 'Stang's sound quite a bit. |  Here's what all the fuss is...  Here's what all the fuss is about. R2C Performance Products' cold-air intake system for '05-'09 Mustang GTs (PN CAI10502; $399.95; a V-6 system also is available) comes complete with all of the pieces shown here (large-size clamps also are included). The square-shaped, 3-inch inlet tube highlights the unique setup. From a technical perspective, air tends to want to keep moving in a straight line when it enters a CAI system. In a round-tube setup, air stays close to the short wall of the tube and thus the long wall experiences little flow. With R2C's trapezoidal shape, the distribution profile is said to be more consistent across the entire tube. |  Metco's Shelby throttle-body...  Metco's Shelby throttle-body adapter (PN MTB0001; $329.99) includes a brand-new, Shelby GT500 throttle body, a CNC-machined, ½-inch-thick billet adapter plate, billet mounting-bolt bushings, and stainless steel bolts. The upgrade throttle body is sold as a complete assembly, so there's no need to transfer parts from the stock throttle body to the new piece prior to installing it. |
 With our project car safely...  With our project car safely raised on a twin-post hoist, Realspeed technician, Rodney Yu, removes the stock mufflers and post-catalytic tubing. |  Rodney and Rob DeMartinis...  Rodney and Rob DeMartinis tag-team the exhaust installation, which entails simply positioning and securing the after-cat tubing and mufflers on each side. Kooks provides all of the clamps that are necessary, and the system fits cleanly beneath the chassis in the same location as the OEM parts. |  The stainless mufflers and...  The stainless mufflers and polished pipes look great, and sound a lot better than the barely audible factory exhaust pieces. With this step complete, the crew lowers our tester and moves it onto the chassis dyno for a spin on its roller. |