Check out behind the scenes testing of the all-new 2016 Cobra Jet here.

Many Mustang enthusiasts are well aware of the Cobra Jet Mustang and the history behind this legendary racecar bred exclusively for the drag strip.

But what some enthusiasts may not be up to speed on is the assembly process of the Cobra Jet. With only 50 models produced per year, the latest S550 platform Cobra Jet shares over 75-percent of its components with the 2016 Mustang GT model, yet the Cobra Jet boasts an eight-second quarter-mile capability. Ford Performance gives us an inside look at how the 2016 Cobra Jet is transformed from a body-in-white production Mustang to a drag racing certified all-out racecar ready to purchase.

The build process of the Cobra Jet is quite interesting. It’s a fascinating symphony between Ford Performance, FRAP, and Watson Racing to create one of the fastest Mustangs ever produced. According to Ford Performance, the Cobra Jet is impossible to build at a higher volume at the plant. Thus, the journey begins with the production of a body-in-white model at Ford’s Flat Rock Assembly Plant located in Flat Rock, Michigan where the current generation S550 platform Mustang is produced. After the body-in-white model has been assembled and prepped using an e-coat primer to prevent panel corrosion at the FRAP location, the semi-prepped S550 model is then sent to Watson Racing for an NHRA 8.50-second ET certified 10-point chromoly-steel cage. The company also modifies the body-in-white by fabricating a set of four-link mounts in the rear of the body and modifying the floor pan with a set of access panels.

The newly modified body is then set back to the FRAP location, which takes care of NHRA specifications on the all-new Cobra Jet with installing the main wiring harness for all of the vehicle’s electronics. Using an electrical bulkhead panel installed on the passenger side firewall, technicians route the battery cable towards the trunk and install an electrical kill switch mounted at the rear quarter panel.

FRAP also paints the newly fabricated cage and interior in either one of two color choices, Oxford White or Deep Impact Blue. Components for the Cobra Jet are then picked from a specific parts bin from a special build sheet provided to each technician, which are unique to each Cobra Jet being built. Now here’s where things get interesting. Ford Performance prides itself with the Cobra Jet in using only ‘go-fast’ parts and a few mandatory safety-related components. In laymen’s terms, the Cobra Jet lives up to it’s barebones/minimalist racecar reputation. Unlike the production Mustang models, the Cobra Jet has shed all of the heavy and unnecessary (at least in this case) insulation, seam sealers, and sound deadening material to save a significant amount of weight.

Engineers have even taken weight savings a step further by keeping all wiring to a minimum in the Cobra Jet. Continuing the path to weight savings, Ford teamed up with Aeromotive Inc to create a Cobra Jet specific fuel delivery system. The system is comprised of the company’s Stealth six-gallon aluminum fuel cell which uses the company’s Eliminator fuel pump and filter which is mounted in the trunk of the Cobra Jet.

Technicians installing many components by hand on the all-new Cobra Jet at the FRAP.

Next up on the build list is assembling the interior and the engine bay partially. While still a dedicated factory built racecar, the Cobra Jet does receive some of the ‘plush’ interior bits from the production GT, such as the carpet and headliner.

Ford chose to include these interior bits to give enthusiasts a feeling of higher quality in the Cobra Jet. Other interior bits include a preassembled instrument panel using an Auto Meter Monster Tachometer and a Hurst Quarter Stick shifter mounted on a transmission shifter bracket.

Ensuring an easy installation of the engine and transmission in the Cobra Jet is simplified by mounting the engine cradle to the radiator. This is accomplished by using a custom fabricated metal stand that houses the assembly, allowing it to be rolled under the body for installation. Technicians lower the Cobra Jet body onto the stand and bolt the engine cradle into place. Built and engineered specifically for the Cobra Jet model to save weight, the cooling system assembly and Aerospace brake components are then fitted to the vehicle. The Cobra Jet also features a line-lock mechanism for the front brake components, and an air-and-oil catch can is installed in the intercooler coolant reservoir.

During the second portion of this segment, Ford Performance goes in-depth and explains the installation of the engine, transmission, and the cooling system specific to the Cobra Jet.

Stay up to date on the Cobra Jet manufacturing process as we bring you updates at a later date to find out how the team at Ford Performance transforms a body-in-white Mustang to a Cobra Jet in as little as six weeks time.