FORD

New generation Mustang was shaped by the wind

Using a wind tunnel to test a vehicle's aerodynamics is nothing new. The 1936 Chrysler Imperial Airflow was the first car to be designed using this device and optimized for smooth airflow. But to take the design of the next Mustang Dark Horse to the next level, Ford combined the latest wind tunnel technology with the equivalent of a vehicle-sized treadmill.

Ford calls the new development the Rolling Road Wind Tunnel, or RRWT. The device is capable of simulating wind and road surface speeds of up to 200 mph. Ford released a statement revealing that the system will be used to test "efficient, performance-oriented vehicles across Ford's entire lineup - including Ford's next generation of electric, hybrid and gas vehicles."

“The amount of air moved through our wind tunnel is enough to fill a K-Class airship in just over 5 seconds,” said John Toth, Ford North America wind tunnel engineering supervisor.

Ford's new Rolling Road Wind Tunnel, or RRWT, is capable of simulating winds and surface speeds of up to 200 mph.(image above)

Moving is better than standing still...Ford says one of the main benefits of the RRWT is that it “provides more accurate data in terms of wind drag and downforce compared to other previous wind tunnel designs, which are key factors when optimizing reach and efficiency.”

The new tunnel also allows for more in-house testing that simulates open road conditions, which can help reduce design costs while accelerating the design process.

“The closer we can get to reality in the lab, the better and faster we can create more energy efficient vehicles with great stability on the road and on the track,” said Toth. “Testing while the wheels and tires are moving is key to improving aerodynamics for track-ready vehicles like the Mustang Dark Horse that have to balance aerodynamic drag and downforce.”

Computer-aided design and computational flow dynamics simulated on a computer have long been used to optimize shapes, but the new five-lane bearing system can replicate real-world drag through an aerodynamic tunnel that allows Ford bring the road to the vehicle instead of the vehicle to the road.

To test optimal aerodynamic performance, each wheel on the vehicle is fitted with its own belt, forming the first four belts. A large fifth belt runs under the center of the vehicle to study the aerodynamics of the vehicle's undertray when in motion.

A crane is used to switch between five-belt and single-belt systems – an industrial-size plug-and-play. The single belt, which operates at up to 200mph, opens up a new generation of high-speed performance vehicle testing.

The Dark Horse starts out as a guinea pig...Automakers always like to optimize aerodynamics as this allows them to achieve fuel economy goals without detuning the engine or downsizing. Reduced aerodynamic drag directly translates to greater efficiency. But there are also performance benefits, and Ford officials noted the all-new Mustang Dark Horse is among the first of many vehicles to be tested in this new wind tunnel.

When designing vehicles like the Dark Horse, which will prioritize track-ready performance, aerodynamicists often trade off low drag for higher downforce, which helps the cars grip the road or track and improves the handling feel when cornering. When air is pushing down on a vehicle, it offers the traction advantages of higher weight without adding the additional mass that must be accelerated.

One of the benefits of wind tunnel testing over the years is the simple invention called the Gurney flap – named after legendary racing driver and designer Dan Gurney. The Dark Horse Mustang comes with an available Gurney flap, which is an extra plate attached to the rear wing to help generate additional downforce, as well as three vertical plates coming out of the lower body near each front wheel called strakes. The strakes help stop airflow, generating more vacuum-based downforce at the bottom of the vehicle, which can help the car grip better in corners at higher speeds.

What We Know About the Dark Horse...Overall, the Dark Horse Mustang includes several changes and additional features, including a redesigned front bumper, a lower valance, a spoiler, and unique wheels. The front design is optimized to increase airflow for engine cooling, brakes and air intake, while also reducing front lift.

On the Dark Horse Mustang, the lower spoiler and splitter are unique, allowing the car to be tuned for more downforce. Dark Horse's updated handling package features a unique splitter, spoiler and wheels — changes that may seem small but make all the difference when you hit the road or track with performance in mind.

“We spent approximately 250 hours in the wind tunnel developing the 2024 Ford Mustang, which includes the Dark Horse,” said Jonathan Gesek, Mustang and Bronco program aerodynamicist. “The aerodynamics of the Dark Horse Mustang, along with a number of other factors, created the most track- and street-friendly 5.0-liter Mustang to date.”

A naturally aspirated 5.0-liter Coyote engine powers the Mustang Dark Horse, producing 500 horsepower through a Tremec 6-speed manual transmission or optional 10-speed automatic transmission. Ford's MagneRide active damping system is standard, but a handling package is optional.

Expect the 2024 Mustang Dark Horse to hit showrooms later this year. The Dark Horse and all 2024 Mustangs will be produced at Ford's Flat Rock Assembly Plant in Flat Rock, Michigan.

Jeff Zurschmeide