2008 Roush Mustang P-51A - Ready for Flight

Building a P-51A was anything but a haphazard process, as the conversion was guided, in exquisite detail, by this reference manual. This type of repeatability and attention to a production-style process was necessary in a vehicle that brings with it 510 hp and a three-year/36,000-mile warranty.

The production-line nature of the P-51A build process was demonstrated by this complicated-looking rig. It precisely located the clips to which the P-51A's rear quarter-window louvers were screwed.

The factory spoiler came off. To provide subtle contrast to the P-51A's Vapor Metallic hue, the Roush rear wing and hoodscoop were finished in Ford's Satin Silver. This contrast was intentional, reminiscent of the slight variation in panel coloration often seen on aluminum-skinned WWII aircraft.

One of the first disassembly steps was to remove the stock cloth buckets and rear seats. These went to a dedicated trim department for reconstruction, as we'll see in upcoming images. Aside from the reworked seats, the P-51A's cabin enhancements included a Roush electroluminescent gauge cluster, aluminum pedal trim, doorsill plates, a carbon-fiber-look dash trim, and P-51A-embroidered floor mats.

There was a rush to get the GT Three-Valve modulars prepared for removal and stripped of the factory components that wouldn't be reused. As the starting point of this process, all engine and accessory fluids had to be drained. Incidentally, the engine (well, at least the block and heads) that came out of any given car went back into that same car.

Once sufficiently disconnected, the engine and transmission were left attached to the K-member and dropped as a complete unit from the bottom. Roush Industries built these hydraulically actuated cradles specifically for removal and reinstallation of the powertrain assemblies. The removal operation was a team effort with one man slowly raising the hoist and car while the other two simultaneously watched for issues while gently lowering the cradle. Notice that the front fascia and struts were also gone at this point.

After further component stripping, including unbolting the starter, tranny, clutch, and flywheel, the long-block was separated from the K-member. It was then sent to the engine crew at Performance Assembly Solutions, a Roush-established, joint-venture company housed in the same building, for teardown and rebuild.

With the K-member still firmly pegged to the cradle, the P-51A's 14-inch rotors and four-piston calipers were bolted in place, along with their braided flex lines. A Roush Stage 3 suspension kit (dampers, springs, sway bars), 18-inch forged chrome rims, and high-performance rubber are part of the P-51A package.

Out back, the fuel tank was removed, and on the work bench, the GT fuel pump was replaced with a Shelby GT500-style twin-pump assembly. This also required the addition of a second pump-driver module and running additional power wiring the length of the car. The P-51A's Stage 3-spec rear suspension components were mostly installed here. In this photo, only the rear brakes remain to be upgraded. Here's a factoid: Roush Stage 3 suspension hardware (except for the springs) is red; Stage 2 counterparts are blue.

To blend in, the radiator support and A/C condenser area were sprayed satin black behind the P-51A's assertive fascia and horizontal-bar black grille. The car's new intercooler heat exchanger and pump were installed and plumbed before the fascia went on.

The GT engine harness got some needed modifications on the work bench, including relocating the air-charge temp (ACT) function from the mass air sensor connector to a separate sensor that reads blower discharge temperature. Also, the throttle position sensor harness was repositioned to account for the new throttle-body location.

Meanwhile, over in the interior trim department, the front and rear seats were disassembled and deskinned of their cloth upholstery. On the buckets, the bottom cushion foam was retained, while the seatbacks received a new, more supportive foam structure with more aggressive side bolsters. The rear seats were reupholstered in leather with suede inserts to match the buckets.