Re: 302 upgrade to 302 Boss
An internal combustion engine is basically a large air pump. To increase the power level, you need to do three basic things: get more air into the engine, get more air through the engine and get more air out of the engine. In other words, you need to improve the air intake tract, the cylinder heads and camshaft and the exhaust system.
The factory intake manifold has a rather puny 58mm throttle body and quite restrictive runners in the manifold itself. There are many choices available in the aftermarket from companies like Ford Racing Performance Parts, Trick Flow, Edelbrock and BBK among others. A new intake and larger throttle body will help more air get into the engine.
The cylinder heads and camshaft in your car are it's biggest restriction. Again, most of the companies listed above make cylinders heads, as well as Air Flow Research. There are many specialty cam companies in addition to those listed above.
The exhaust system consists of three basic components: The headers, the intermediate pipe with the catalytic converters, and the after-cat muffler and tailpipe assembly. A less restrictive cat-back exhaust system is usually the first modification that most Mustang owners do. In addition to freeing up a few horsepower, it makes the car sound like a Mustang. If you upgrade the headers to a larger diameter and swap out the intermediate pipe for one with less-restrictive cats or a cat-less one you will notice an immediate improvement in performance.
Your car was rated by Ford at 225 horsepower at the crankshaft. The Boss 302 was (very conservatively) rated at 290 horsepower. My 93, with the modifications in my signature has 342 horsepower according to a Dynojet dynamometer.
This is just a very brief overview of what it takes to make more horsepower with your car. There are many more pieces to the equation that would take too long to detail. Things like larger fuel injectors, higher volume fuel pumps, underdrive pullies, rear end gears and many more. If you are really interested in learning more about your car, I'd recommend the book The Official Ford Mustang 5.0: Technical Reference & Performance Handbook : 1979 Through 1993 (Ford) by Al Kirschenbaum It goes into great detail about these cars and will help you understand more about them. Also, the forums on websites like my5oh.com and stangnet.com are very good places to learn about making more power from your car.
If you really want to get into this, learn as much as you can. If you have a local Mustang club, join it. Club people are usually more than happy to help a novice out. If there are any Mustang shows in your area, go to them. Again, the folks there are glad to help educate you.
1993 5.0 LX 'Vert
GT-40X303 heads, E-cam, 1.6 roller rockers,
Cobra intake, Edelbrock 65mm t/b, 73 mm C&L, CAI,
24 lb injectors, AFPR, 3.73's, March underdrives.
FRPP headers, Bassani catted X, SLP Loudmouth.
This thing is loud!!!
Pony R's with Eagle ZR's, stock AOD.
Cervini's Air Extractor hood
2003 GT seats
Springtime Edition mirrors & wing
ff member 157