Turbosmart’s S550 Mustang Showcases EcoBoost Performance

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Many of Ford’s cars and trucks now on the market are available with some sort of EcoBoost engine. For the most part, this means turbocharged inline four-cylinders of several sizes as well as a number of turbo V6s. Models available with an EcoBoost engine include the F-150, Focus ST, Fiesta ST and now also the pretty badass all-wheel-drive Focus RS.

But what we are really excited about as of late is the fact that an EcoBoost 2.3-liter turbo four-cylinder is also available in the S550 Mustang, and is now going into its third model year with the 2017s. It also got Marty Staggs very intrigued with these cars as well – enough so that he went out and bought the black 2015 Performance-Pack-equipped S550 EcoBoost you see here.

Not only is Marty a big fan of the new turbo S550; he also happens to be the Vice President and General Manager of Turbosmart USA, the American division of a company with its global headquarters in Australia.

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“We purchased this S550 for the company’s use as an R&D test bed for new Turbosmart products specific to this platform,” Marty told us. “In addition, it serves as a regular commuter car as well as making regular appearances at various trade and car shows; including where it was on display at the 2015 SEMA Show in the Garrett Turbochargers booth.”

Marty said that when Ford originally announced their new Ecoboost program, Turbosmart started its own development program to manufacture components that would improve the performance and reliability of EcoBoost-equipped Ford cars, and even trucks (since Turbosmart is a manufacturer of performance products for turbocharged vehicles).

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If you are going to make more boost, you need to be able to cool it down to maximize efficiency. – Marty Staggs, Turbosmart USA

“We originally started with the Focus ST and found some good opportunity for performance improvements when it comes to the wastegate actuator and bypass/blow-off valve,” Marty explained. “This program has been very successful for Turbosmart. We then turned our attention to the Fiesta ST and then the F150.”

When Ford announced that they would offer the new S550 Mustang with an optional 2.3-liter Ecoboost engine (and add to that the fact that it would be a global vehicle), Marty said they knew they would be very into developing product for it.

“As with every vehicle we make parts for, we needed to acquire a car to do our development,” he said. “We ended up getting one of the first production EcoBoost S550s on the market.”

“We immediately went to work analyzing the power production and boost curves,” Marty elaborated about the theory of building power with the EcoBoost.

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Build List

“It’s a great car in stock form, but we found many of the same opportunities for improvement that we recognized with the other Ecoboost vehicles held true on the Mustang as well.

“Turbosmart now manufactures wastegate actuators, charge pipes, blow-off valves, and bypass valves for this car, and they have become very popular. I was not going to be satisfied with a warmed-over, lightly modified car for our project, and I was aware that there was great deal more potential.

“I contacted Garrett Turbochargers and shared our data (Garrett is the OEM manufacturer of the stock turbo on the Mustang), and told them I wanted to build a new turbo kit that would spool up like stock, but would also make 400 horsepower and carry that power all the way to redline.”

Marty said that Garrett suggested its GTX2867R turbocharger, and also said they were absolutely right on about the suggestion.

Marty further detailed the EcoBoost’s performance trajectory, saying that if you are going to make more boost, you need to be able to cool it down to maximize efficiently.

Marty further detailed the EcoBoost’s performance trajectory, saying that if you are going to make more boost, you need to be able to cool it down to maximize efficiently.

“We are using an Ambient Thermal Management large-core air-to-air intercooler, along with a custom Tune+/AEM methanol injection system,” Marty explained.

“Additionally, turbochargers create a lot of radiant heat. To help combat that, we went with DCI Performance thermal management products. DCI is a tier-one OEM supplier to Ford and GM, so the DCI under-body heat shield kit that they make specifically for the S550 was installed; as well as numerous sections of XT5000 pipe shielding and their XT Ultimate cat shield.”

In the engine compartment, a turbine heat shield was fabbed up using DCI XT5000 material and any hoses and wires around the turbo area were wrapped using DCI Thermashield.

Marty said that in the engine compartment, a turbine heat shield was fabbed up using DCI XT5000 material, and any hoses and wires around the turbo area were wrapped using DCI Thermashield.

As for tuning, Marty told us that to help dial the in ECU (and really tie it all together), their good friend Adam Brunson at Tune+ is their go-to guy. “He is one of the best calibrators in the U.S. for Ford Ecoboost cars,” Marty proclaimed. “We also use a Cobb Tuning Accessport as the interface, and there are more than 14 different maps to choose from. Adam was instrumental in getting the power curve set to my liking, and really making the car a pleasure to drive both on and off the track.”

After discussing what Turbosmart was doing, Garrett asked Marty if they would like to display the car in their booth at the 2015 SEMA Show. “Of course we would,” he said.

Turbosmart then changed its direction with the car a bit, and decided to do more to the car to make it a better representative for Turbosmart, Garrett, and the other companies involved.

Marty said that the shocks and struts were upgraded to the new Pedders Suspension ExtremeXA coil-over kit. The car sits exactly right with the parts directly out of the box. The IRS has also been fitted with a Whiteline Suspension anti sway bar and bushing inserts, and a pair of UPR Products billet vertical links also for the IRS.

On the aesthetics side, Marty enlisted Sky Print Media for the striping and decals. He also owns an S197 GT500, and is quite partial to the way full stripes over-the-car and on-the-rocker-panels look.

"Alex at Skyprint took that and came up with the triple stripe combination that uses police reflective-style inner stripes that basically changes colors from black to silver, depending on the lighting and angle you are looking at it from," Marty told us.

“Alex at Skyprint took that and came up with the triple stripe combination that uses police reflective-style inner stripes that basically changes colors from black to silver, depending on the lighting and angle you are looking at it from,” Marty told us.

Marty also went with carbon-fiber body trim panels from TruFiber. All of the textured plastic body-trim pieces on the car have been replaced with real carbon fiber as well.

Since the nose on the Ecoboost Mustang is different than the Coyote 5.0-powered GT, there was no front carbon splitter available and it is believed that one hasn’t been produced. So Marty bought a new front underbelly pan for an S550 GT from Ford, and modified the nose of the car to use the GT carbon-fiber front end parts. It took a bit of work, but the whole setup was seamlessly incorporated.

Of the car in its current state, Marty further commented: “I really enjoy this car so I will continue to use it as a daily driver. Turbosmart will also continue to use it as a platform for new-product development and testing and I also intend to do some autocrossing with it.”

Under the hood, an engine cover from Anderson Composites and other textured plastic parts have also been replaced with real carbon fiber. The fog and side marker lights were also replaced with Switchback LEDs.

To summarize, power output has been greatly enhanced with the following bits and begins with a Turbosmart complete custom turbo system featuring the aforementioned Garrett GTX2867R V-banded turbo.

A Cobb Accessport with Tune+ custom calibration makes it all work, and an X-Force 3-inch turbo-back exhaust system with a 100-cell racing cat and dual Varex remote-controlled mufflers (to alter sound levels) complete the power-adding picture.

A Cobb Tuning Accessport with Tune+ custom calibration makes it all work, and an X-Force USA 3-inch turbo-back exhaust system with a 100-cell racing cat and dual Varex remote-controlled mufflers (to alter sound levels) complete the power-adding picture.

12GRA Turbosmart Compgate-40 external wastegate was also added as well as an Ambient Thermal Management air/air intercooler. There are also Turbsosmart charge pipes, a Turbosmart Raceport blow-off valve (BOV), a custom Turbosmart CAI and AEM methanol injection.

The result on crummy California 91-octane pump gas is 380 horsepower and 390 lb-ft of torque at the rear wheels.

Putting it all down are mostly stock drivetrain bits including the MT-82 six-speed manual trans and the car’s mostly stock IRS with its aforementioned upgrades. Although an Australian Clutch Services Xtreme Performance single-disc clutch was added, and it’s good for more than 600 horsepower and is seven pounds lighter than the factory dual-mass setup. Marty reports that it engages just as smoothly as stock, and that its lighter weight also helps the engine rev much quicker.

And so, there’s the fundamental idea on how the latest in high-tech Mustang performance is fused with upgrades from one of the aftermarket’s well-known turbocharger accessory suppliers to create a formidable S550 EcoBoost. We sure think it’s awesome, and if you’re looking for ways to upgrade your turbo S550, this car is clearly a good place to begin your research.

The RAYS Gram Light 57Xtreme wheels are 19x9.5s front and 19x10.5s at the rear. The Nitto NT05 tires are 275/35ZR19s (front) and 305/35ZR19s (rear). StopTech 6-piston disc brakes were also fitted at the front of the car.

About the author

Miles Cook

Miles Cook began his automotive writing career at SEMA, then spent a year at Turbo & Hi-Tech Performance covering the ’90s import scene. He then worked for Car Craft magazine, where he became the de-facto Ford guy on the staff. Next, he went to Mustang Monthly where all Mustangs were the mainstay. Miles is well versed in vintage and late model Mustangs as well as GM, Ford, and Mopar musclecars. His expansive background ensures that Miles is right at home writing for Power Automedia.
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