1969 Mustang BOSS 302.0: DSE Suspension, 5.0, V8TV Build

[oestek]

https://static1.pt-content.com/images/pt/2012/09/V8TV_BOSS302L-1.jpg

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!

[xplane]

Great looking project, will be keeping a close eye on your progress. Excellent digital documentation so far!

[compos mentis]

https://static1.pt-content.com/images/pt/2012/09/V8TV_BOSS302L-1.jpg

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!



Sounds like another very interesting project for you guys Kevin.:twothumbs

Great rendering obviously as well.

[85coupe50]

That is awesome... New Detroit Speed parts... Love the way all that is looking!

[chunger]

No updates yet?

Ha! Anyway, should be another cool project for you guys. Can't wait to see how it turns out.

[oestek]

Wow, glad to see the positive feedback! Thanks!

We're very stoked about this one as well.

Here's what we're starting with:

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_071012_018JPG-1.jpg

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_071012_095JPG-1.jpg

It's a pretty clean AZ car.

[C6Z06]

Very, Very Cool.

I'm biased of course, but the rendering is drop dead gorgeous.

So what do you suppose this bad boy and the 69 Camaro you are also building right now will talk about when you leave them alone together at night?

[oestek]

Right now, I'm pretty sure both cars would be screaming in pain right now if they could talk!

[oestek]

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

https://static1.pt-content.com/images/pt/2012/09/BOSS302_Beginning-1.jpg

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

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_071112_095JPG-1.jpg

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

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_071112_075JPG-1.jpg

Some grinding here and there revealed ugliness in the doors.

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_071612_27JPG-1.jpg

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

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_071612_46JPG-1.jpg

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_071612_47JPG-1.jpg

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.

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_072512_20JPG-1.jpg

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.

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_072012_02JPG-1.jpg

Next up, the media blaster!

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_072012_18JPG-1.jpg

[oestek]

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

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_080312_16JPG-1.jpg



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.

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_080312_03JPG-1.jpg


https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_080312_08JPG-1.jpg

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.

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_080812_09JPG-1.jpg

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

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_080312_10JPG-1.jpg

After the initial inspection, the crew spun the car on the Autwirler 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.

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_080912_01JPG-1.jpg

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

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_080912_12JPG-1.jpg

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

[oestek]

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.

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_072512_07JPG-1.jpg

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.

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_072512_54JPG-1.jpg

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.

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_072512_68JPG-1.jpg

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_072512_63JPG-1.jpg

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_072512_57JPG-1.jpg

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

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_072512_31JPG-1.jpg


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.

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_081612_20JPG-1.jpg

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_081612_16JPG-1.jpg

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_081612_38JPG-1.jpg

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_081612_36JPG-1.jpg

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_082012_08JPG-1.jpg

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_082012_03JPG-1.jpg


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.


https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_082312_14JPG-1.jpg

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

https://static1.pt-content.com/images/pt/2012/09/69_Boss3020_082712_04JPG-1.jpg

[6fastback7]

DSE installation video up soon? what transmission are you running behind the Coyote? lots of cutting to get the transmission in?

[oestek]

The suspension video and pics will be up next week. We are going to run a TKO 600 in the car, but we have not installed it yet, so I cannot speak to the trans tunnel cutting. We're still waiting on the engine mounts to arrive from DSE to place everything. Stay tuned!

[Hotwhilz]

Just curious, Boss 302 without the Ford Boss 302 intake? Is it a packaging matter, after getting the chance to try a regular 5.0 and the Boss version, I got to say that the Ford racing Boss Intake is worth a scoop!

Nice project

[LeighP]

School me a little with the power steering.....is it not an option to run the electric powersteering pump system that the Coyotes normally use...or it it just cost effective to go with an Engine Driven Pump power steer system?

[john31s]

School me a little with the power steering.....is it not an option to run the electric powersteering pump system that the Coyotes normally use...or it it just cost effective to go with an Engine Driven Pump power steer system?

If I'm not mistaken there is no power steering pump at all, the steering rack is moved by an electric motor not hydraulic fluid.

[LeighP]

Ahhhh....OK, thought they were jsut using an electric pump. Explains the need for an EDP.

[oestek]

Correct, they use an electric motor on the steering column and a manual rack. Flaming River is making such an animal, which seems to be based on the Ford system, but we are using the DSE rack. We also require the pump for the Hydratech hydraulic assist brake booster.

Flaming River unit:

https://static1.pt-content.com/images/noimg.gif

[Kybosh]

You couldn't have started this project at a better time. My father has a '70 boss 302 and he has been asking me what kind of suspension mods are out there that people are doing. He wants to keep it mostly original except for the suspension. I'll def be pointing him in this direction.

Very much looking forward to seeing future updates,

[MSTSFabbed]

Never seen anyone mask with aluminum foil. Not a bad idea!

The motor looks sweet!! Keep up the good work!

[AUTODYNAMICS]

Very cool

[oestek]

You couldn't have started this project at a better time. My father has a '70 boss 302 and he has been asking me what kind of suspension mods are out there that people are doing. He wants to keep it mostly original except for the suspension. I'll def be pointing him in this direction.

Very much looking forward to seeing future updates,

Hope this thread helps!

[oestek]

Never seen anyone mask with aluminum foil. Not a bad idea!

The motor looks sweet!! Keep up the good work!

The foil is a trick we use when you have a super-complex shape to mask. Works well!

[oestek]

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.



dlN-9FgALnA

Click to https://static1.pt-content.com/images/pt/2012/09/sub4sub-1.gif (http://www.youtube.com/subscription_center?add_user=v8tv) and never miss a BOSS 302.0 video!

[oestek]

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!


-EuFC2O9_Sc

[Nova1978]

Correct, they use an electric motor on the steering column and a manual rack. Flaming River is making such an animal, which seems to be based on the Ford system, but we are using the DSE rack. We also require the pump for the Hydratech hydraulic assist brake booster.

Flaming River unit:





The new mustang uses an electric motor mounted on the rack housing to provide assist torque which is called a REPS system (Rack Electric Power Steering). The unit in the picture is a column mounted EPS system (CEPS). EPS stands for electric power steering. Usually vehicles heavier than 3500 lbs or high performance vehicles use a REPS system due to the high loads that would be seen in the system. Also, REPS allows for more feedback at the handwheel, which is more desireable in a high performance vehicle. With a CEPS unit, the intermediate shaft going from the column to the rack sees full assist torque and needs to be beefed up. With a REPS system or a hydraulic power steering system, the intermediate shaft only sees hand wheel torque. I don't know much about the system you have selected, but I do have experience in electric power steering and I'm not sure you will like the feedback or lack thereof you will see with a column mounted system. Not to take away from this build, just wanted to make sure you will have the correct parts/expectation from that system. A vehicle like the chevy sonic has a CEPS system.

[chunger]

Neat Kevin. This DSE system looks like something totally different from everything else out there for early Mustangs. I'll be curious to get your driving impressions once it's done.

Any idea of what these systems go for?

[oestek]

The new mustang uses an electric motor mounted on the rack housing to provide assist torque which is called a REPS system (Rack Electric Power Steering). The unit in the picture is a column mounted EPS system (CEPS). EPS stands for electric power steering. Usually vehicles heavier than 3500 lbs or high performance vehicles use a REPS system due to the high loads that would be seen in the system. Also, REPS allows for more feedback at the handwheel, which is more desireable in a high performance vehicle. With a CEPS unit, the intermediate shaft going from the column to the rack sees full assist torque and needs to be beefed up. With a REPS system or a hydraulic power steering system, the intermediate shaft only sees hand wheel torque. I don't know much about the system you have selected, but I do have experience in electric power steering and I'm not sure you will like the feedback or lack thereof you will see with a column mounted system. Not to take away from this build, just wanted to make sure you will have the correct parts/expectation from that system. A vehicle like the chevy sonic has a CEPS system.

We're not using either of these, I just forwarded the info along because someone asked. We're using the DSE rack and a Type II steering pump mounted to the Coyote with the Vintage Air Frontrunner accessory drive system, a traditional power steering setup.

[migg400]

Pretty AWSOME build!!

[Rols574]

updates?

[lilian]

on their site they isntalled rear suspension,, very nice build !! thanks for the vids

[oestek]

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.


BpEX9S_QHJ0

[Twentyover]

Correct, they use an electric motor on the steering column and a manual rack. Flaming River is making such an animal, which seems to be based on the Ford system, but we are using the DSE rack. We also require the pump for the Hydratech hydraulic assist brake booster.

Flaming River unit:

https://static1.pt-content.com/images/noimg.gif

As an informational aside, American Powertrain has a column EPAS deal similar to the Flaming River part, at like 40% of the flaming river cost. A compadre in OZ is using one in a wide-tired MGC, and he reports little compromise in road feel and feedback. Basedon his inpit, thinking I may go that way also.

[MichaelLeeHearn]

Here is the company that makes the units for Flaming river, they have several other options.

http://www.wiringlooms.com/Products/EPAS/

[Evoix]

I was waiting for an update to this thread!

[Shotaro]

Is this a forsale car!??

[oestek]

Is this a forsale car!??

No sir, but it will be back in the shop for some updates soon.

[Jeff70]

Was it ever finished?

[oestek]

Was it ever finished?

The customer had us put this project on hold, but now it's back in line for action.

[qnitro]

any updates?