Anyone who has paid even the slightest bit of attention to the various forms of automotive competition over the past three decades will recognize the name Jack Roush. He has designed, built, modified, or somehow been connected with cars showing up in winners' circles of every racing venue in the country.
The shop door to Jack Roush Performance Engineering rolled up in 1976 and since then the company has grown to employ over 2,000 people in 50 locations worldwide. Operations now include marketing and product development services for major manufacturers, the manufacture of components and performance cars, and, as of late, a line of Roush-engineered Ford-based performance engines.
Over the last 25 years the crew at Roush Performance has put together thousands of engines that have raced and won in drag, road, oval track racing, and set numerous records at Bonneville. With that background, and the general reputation Roush had established, several builders of reproduction Cobras called looking for a "better" crate motor. Roush responded and the end result of those inquiries is that you can now have a Ford engine built to their exacting tolerances and a two-year/24,000-mile limited warranty.
Currently several series of engines are being offered in both carbureted and fuel-injected form. All engines are hot-tested, horsepower and torque are verified on a dynamometer, and serial numbers issued.
Unlike some engine suppliers that offer a base engine with a few options, it's hard to get your hands around everything Roush is capable of providing. They can perform virtually any machining function in-house, in fact they make their own pulleys, grind cams, CNC port heads, and can turn raw castings of blocks, heads and manifolds into finished pieces. There is little they can't do, so if you want it, they can probably supply it, but in most cases you'll find something off the rack that will fit.
To make sure there's something for almost everybody, Roush Performance engines come in several series. The AL series is based on the Windsor small-block (FE and 460 based engines are also available) and comes in displacements of 327, 342, 358, and 392 ci. These engines use two-bolt main blocks that come with a girdle to stabilize the bottom end, cast cranks, I-beam rods, roller-hydraulic cams, and Roush aluminum heads. With all the variations within the series we don't have room to give all the specs (check their Web site), however we can say the 327Al puts out 410 hp with 390 lb-ft torque, and the 342 Al makes 430 hp with 415 lb-ft torque.
While the AL series of engines are ideal for street rods, the Windsor-based R series is available for those looking for something more robust; displacements are 327, 342, 402, and 427. Like all Roush Performance engines, the R series are built on blocks that allow for an overbore down the line. In other words, these engines aren't punched to the max right off the bat, so if it's ever necessary to bore the block further during a rebuild there's enough metal left to do it.
To insure durability the R series engines use forged internal components and the heads are fully CNC ported. The 327R makes 425 hp and 390 lb-ft torque, while the 342R churns out 450 hp with 420 lb-ft torque. Both are based on production blocks and use forged cranks and pistons along with H-beam rods and roller hydraulic cams. If you're looking for more, step up to the 4-inch stroke 402. Based on a Ford Racing Sportsman block, you'll have 515 hp and 500 lb-ft torque. Of course if that's not enough check out the 427R. A Dart Iron Eagle 4-bolt block is stuffed with enough Roush parts and pieces to make 550hp/535 lb-ft torque, and it still carries the same warranty the rest of the engines do.
If you're still not satisfied, Roush offers a trio of electronically fuel injected engines. The 342 RE uses throttle body and comes with a harness, computer and fuel pump making installation a breeze. The 402 IR comes with an impressive 8-stack, Weber style fuel injection system. This engine makes 500+ hp and 500+ lb-ft torque. And if you're really anxious to shred tires, the injected 427 checks in with 550+ in both the horsepower and torque categories. At this point it should be obvious that Roush Performance has a Ford engine for just about any performance level. Dynoed, checked for leaks, and covered by a warranty, the folks at Roush Performance sum it up best: "We've built engines that have won us championships, now it's your turn--Isn't it time to put a little Jack in your car?"
The machine shop is capable of every process necessary to build a precision engine. In this case a block is being line-honed. | 
A variety of crankshafts are used, depending on the application they may be cast or forged, OEM, or aftermarket. | 
In some cases the customer may have special requests; Roush can handle them. Note the four-bolt mains, rounded counter weights and screw-in soft plugs. |
As we said, Roush is capable of building just about any part. These are semi-finished head castings waiting for a ride through a CNC machine. | 
During assembly the latest in tools and techniques are used. Check out the trick torque wrench. | 
Custom porting for specific applications is done in-house with CNC machines. |
The finished heads are assembled with valve springs and components matched to the cam. |  | 
In most cases double-row, roller timing chains are used. Hydraulic roller cams are used in many installations. |