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It seems like we’ve all been talking about the special edition BOSS 302S Mustang for quite a while now, but the fact is that the first run of twenty cars is happening right now. We were invited to Flat Rock, MI, to see this group of cars being put together and we’ve got lots to tell you.
This special production line had just finished its run of 2011 Cobra Jet Mustangs and switched over for the BOSS 302S. This edition, you may recall, is a track-only Mustang sold by Ford Racing for use in the NASA American Iron series or the GTS class of the World Challenge series. Not to be confused with the BOSS 302 Mustang, or the BOSS 302 Laguna Seca Edition cars, both of which are road-legal, the BOSS 302S
This Mustang uses the same 440 hp, naturally aspirated, 5.0-liter engine that you’d find in the road-going BOSS, except for a remote mounted oil filter. While the 6-speed transmission also is stock, the rear axle differential is changed up to a Torsen unit – universally favored by road racers. The BOSS 302S was first announced as having a maximum production of fifty units, however, George Goddu, head of Ford Racing Performance in North America, indicated today that Ford is willing to be flexible on that number if the market demand justifies it.
The BOSS 302S starts as a Mustang body-in-white. To reduce weight, the factory seam sealer, sound deadener and interior panels are deleted prior to body build. The body in white is sent to a local company, Wilson Engineering, to have a 6-point FIA-legal roll cage installed for driver safety and chassis rigidity. A number of additional changes are made before returning the bodies to the Auto Alliance plant, where the cars are then painted in either Performance White or eye-searing orange.
From there, they are wheeled over to the Ford Racing build line. That is where we pick this story up.
Before a BOSS 302S Mustang gets looking this good, there is a lot of work that goes into getting it ready
After arriving from the paint line, assembly work begins, while the car is still on its dolly. Here, some of the front end pieces such as the ducting, energy absorber and front tow hook hardware have been installed.
There are two parallel build lines in the facility. Now on a cradle, this BOSS 302S has been fitted with reinforcing plates for the rear spoiler. Note the reinforcing bars as well that were installed by the contractor. Interior preparation has started and flank protection is in place to keep those dings and scratches at bay
As the car moves along the line, wiring is installed along with the required auxiliary equipment, such as the Ford Racing aluminum radiator and oil cooler. The steering column is put in place. All of this is in preparation for the last step along this stage, when the car is lifted to receive the front subframe assembly and rear axle.
By the time the front fascia is installed, much of the underhood preparation is complete. The ECU and it's wiring along with the master battery disconnect are in place. Cooling ducts have been installed, just waiting for the front subframe to appear.
And... here it is. If Santa Claus were to leave something special in our garage, this would be the second choice. Of course, the entire BOSS 302S would top our list. The front subframe assembly holds the engine, transmission, steering, suspension and front half of the exhaust system.
An AAI worker prepares to bring it all together. The rear axle and front subframe are in place and the body is ready to receive the new components
Once the body and the rest are together, there are lots of things to connect. In the front, the brake cooling ducts get finished off, along with brake lines and ABS connections. In the rear, the suspension will be assembled, including the upper and lower control arms, as well as the adjustable panhard rod. Installing the driveshaft and wheels make for a major milestone in the build.
Here are the big rollers, just waiting to be installed. It probably won't be long before the new owner has those Pirelli tires shaved.
Finally, the BOSS 302S is standing on its own, err... wheels. There's still plenty of work to do, but the end is in sight.
The center stack was started earlier, but now its time to finish off the inside. Just the bare necessities are included, but the AIM all-in-one instrument panel with GPS logging is a major aid for driver feedback, both during and after a hot session. The Ford Racing quick release steering wheel wraps it up nicely.
Additional interior work involves installing the fire supression system, bottle holder and lines. A remote trunk release cable is installed as well. A sensor package for the ECU is visible on the tunnel, where it is nice and easy to get at.
There's not much left to the doors after removing weight, but they still have to go in. Here they are waiting for a new home.
Now, with glass installed, it's time to finish dressing the engine. A crankcase ventilation system is installed along with the airbox and other necessities.
These cars don't get a Vehicle Identification Number (VIN) because they're not road legal, but they do get an authentic build sequence number instead.
The last steps are to install the adjustable carbon fiber rear wing and the BOSS 302S graphics. Now, its lookin' good and ready to race. This car is ready to race as delivered, so the $79,000 price from Ford Racing is very good compared to what you would spend building it yourself. Considering that the BOSS 302S is fully sorted when you receive it, you'll be having fun sooner than you can say, "Hey, BOSS!"
