"Dave Borne was the 5.0 intake engineer. He did the Boss intake. Early on they had looked at a dual-bore throttle body versus the 80mm stock throttle body. They wanted originally to do a 90 on the program, but for cost reasons it never made it in, and it's only worth 2 or 3 horsepower," Robert explained. "Dave had engineered a manifold that used the dual-bore GT500 throttle body; we tested it with the dual 65s that we sell, and then the monoblade. Each time there was a power improvement. To get that power improvement, we used the 123mm mass air meter that we used on the original '08-'12 Cobra Jets."
Besides the intake and long-tube headers, other mods--like the deeper sump oil pan and larger bore--were worth chunks of power. Sleeving the block for a bigger bore offered the benefits of increased displacement and unshrouding of the valves. However, only the naturally aspirated version of the Cobra Jet receives the bigger bore, as this process could be a weak link when subjected to big boost.
Where the NA version is sleeved to a 94mm bore with sleeves handed down from the T50 Cammer program, the supercharged version is based on Ford Racing's supercharger-friendly Aluminator crate engine (PN M-6007-A50SC). The NA engines are sleeved at Livernois, but both engines are assembled at Ford's crate-engine assembly partner.

Here is the key to making...

Here is the key to making the H-beam rod live in such harsh environs. The only rod failures in the Boss 302R development were attributed to the rod bolt. A move to these ARP 2000 fasteners proved the magic elixir.

Though the 13mm-lift exhaust...

Though the 13mm-lift exhaust cam (PN M-6550-M50BEXH) fell out of the production Boss 302 program, it was eagerly adopted by the Ford Racing team for the Cobra Jet 5.0. These cams are maximized via the use of long-tube headers, and in the case of the NA CJ they added 20 hp to the bottom line.

Try as the they might, Ford...

Try as the they might, Ford Racing engineers and several of its partners tried to better the stock Boss 302 cylinder head (PN M-6049/6050-M50BR). They couldn't do so without making the costly architecture change to larger valves.
Both combos have undergone rigorous testing and tuning on Ford Racing's in-house engine dyno, which serves to prove out the calibration and verify the durability of the combination. "We did a bunch of development on locking the VCT out. If you sweep the cam and find the optimal location and pretend you don't have a phaser, you give up a huge amount of torque," Robert explained. "For a drag race car, it's probably not significant because that loss is below 4,500 rpm. You could argue that on a drag car you'd never be there anyway, but why give up all that torque and add cost? Now you have to eliminate the phasers. The only motivation for doing that is if you were using an engine controller that was not capable of controlling the VCT."
"When we calibrate the Cobra Jet, we sweep it at every 500-rpm increment all the way up to 8,000," Rob added. "We sweep the exhaust cam and find the optimum spot, and we sweep the intake cam to find the optimum spot. Sweep the spark timing and optimize that, then sweep the fuel and optimize that."
It's not too often that a racer can benefit from this level of testing and purchase it in a turnkey combination. Ford Racing takes it right down to tuning it for a specific fuel, which in this case is VP C14 for the naturally aspirated combination and C16 for the supercharged version. That way the team can better troubleshoot issues that racers have in the field.
"We strive for continual improvement in the Cobra Jet brand, and the 2013 is no exception. Every aspect of the car--from steering, to chassis, and especially engine--has been improved. The engine is critical--probably 40 percent of the equation in drag racing--and our dealers and racers said they wanted the 5.0," explained Ford Racing's Jesse Kershaw. "The 5.0 has been an ideal choice, allowing us to develop performance parts and debunk some conventional drag racing myths. We're not just building a race car--we're engineering a Cobra Jet. "

While Ford Racing retained...

While Ford Racing retained the standard Boss 302 valves, they did work with Livernois Motorsports to add a stiffer set of valvesprings to better handle the increased rpm and cylinder pressure. The low back pressure created by the Cobra Jet's open exhaust likely makes these a luxury, but one that's nice to have at 8,100 rpm.

As you may know, the latest...

As you may know, the latest 5.0s love rpm, but the PCM can reel in the revs before the party really gets going. The primary culprit is the high-data-rate wheel that the computer reads to determine crank position.

Ford Racing engineers tweaked...

Ford Racing engineers tweaked the mainstream design by relocating the throttle body and reducing the injector bung.
That product is available under a single part number, M-FR500-CJ, and retails for $85,490 for the naturally aspirated version and $92,990 for the supercharged version. Of course, many of the individual parts, like the Cobra Jet intake manifold, will be available for sale via the Ford Racing Performance Parts catalog. If you weren't able to buy one of the '13 CJs, odds are this program will continue, and it may even expand to see a Trinity 5.8 join the 5.0 under the hood.
"In competition, the Cobra Jet will see more heads-up action. There is excitement around the Cobra Jet and the Brand X competitors, such that we're reliving the enthusiasm of the late '60s with production racing!" Jesse added. "For development, our goal is to continue to offer a competitive vehicle at a price that makes it a value. We do this through continued refinement of the Cobra Jet to meet customer demand and promote the performance attributes of the Mustang. And, despite it's immense popularity and continual back-orders, we plan to continue to limit production to only 50 units annually.
"It's more than a Mustang with bolt-on parts--it's a Cobra Jet." 5.0
Horse Sense: Ford Racing will offer the naturally aspirated Cobra Jet intake as an individual part and it looks to provide a significant horsepower gain over even the vaunted Boss 302 intake manifold.

A testament to how closely...

A testament to how closely Ford Racing worked with mainstream engineers on this program is the new CJ intake manifold (PN M-9424-M50CJ). It was born from CAD data that mainstreamers once considered for the Boss 302 program.

We have long known that opening...

We have long known that opening the air path is key to performance on these modern engines. Whether the airflow is the result of extended rpm or supercharger boost, these race engines must breathe. Ford Racing uses the 123mm Cobra Jet mass air housing on the naturally aspirated combination, and the huge 140mm housing on the supercharged version.

Again, we aren't privy to...

Again, we aren't privy to the real horsepower numbers of the supercharged Coyote 5.0 (PN M-6007-CJ13SC), but we do know that it approaches the performance of the outgoing 5.4 combination, and it will ride in a lighter car. Sounds like a recipe for low e.t.'s. It's also worth noting the Ford Racing approached its horsepower target with a version of the production 2.3 TVS used on the '13 GT500, but the 2.9 Whipple nailed the target with its affordable off-the-shelf package. For the purposes of NHRA Stock Eliminator BB-Stock, this combo is rated at 480 hp and tips the scales around 3,175 pounds.

While the lower intake manifold...

While the lower intake manifold and intercooler are the same parts utilized by Ford Racing Performance Parts for its Coyote supercharger kits, these lower manifolds are port-matched to the CNC'd RoadRunner cylinder heads. FRPP is considering offering this part individually or as part of a Boss-specific supercharger kit.

To facilitate slip-free boost,...

To facilitate slip-free boost, Ford Racing developed a unique 10-rib blower drive system spun by an ATI crank dampener. The team found it was necessary by maxing out the base kit's 2.3-liter blower and 6-rib drive to the point of slippage. With the 10-rib 2.9 and a 3-5/8-inch pulley, they hit their power target. Besides overdriving the blower by 20 percent, the ATI unit is critical from a durability standpoint, as adding a supercharger changes the torsional dynamics of the engine as much as stroking it.

In deference to the extended...

In deference to the extended rpm range of the Cobra Jet engines, Ford Racing chose to underdrive the alternator on these engines. This not only saves the alternator but eliminates the one-way clutch used on the OE engines, which proved it was not up to the rigors of racing in the Boss 302R.
Ford Racing first experimented with Tri-Y long-tubes designed by Coyote engineer Adam Christian. They worked well but would have been expensive to produce. The team found similar performance and easier packaging in American Racing Headers off-the-shelf 1-7/8-inch long-tubes. In the car, those headers are run wide-open out these short dumps, so restriction is minimal.