Our Living Language Most people might think that the slang usage of bad to mean its opposite, “excellent,” is a recent innovation of Black English. While it is of Black English origin, this usage has been recorded for over a century; the first known example dates from 1897. Even earlier, beginning in the 1850s, the word appears in the sense “formidable, very tough,” as applied to persons. Whether or not the two usages are related, they both illustrate a favorite creative device of informal and slang language—using a word to mean the opposite of what it “really” means. This is by no means uncommon; people use words sarcastically to mean the opposite of their actual meanings on a daily basis. What is more unusual is for such a usage to be generally accepted within a larger community. Perhaps when the concepts are as basic as “good” and “bad” this general acceptance is made easier. A similar instance is the word uptight, which in the 1960s enjoyed usage in the sense “excellent” alongside its now-current, negative meaning of “stiff.”
http://www.answers.com/main/ntquery?s=bad&gwp=13

Yes, bad means good in this phrase, but bad-to-the-bone in reference to this engine means it's a powerful, muscular engine right down to the last component. Everything about the engine says "power", "muscle."

"Bad to the Bone

The Mach 1 has a strong heritage that left lasting impressions on muscle car and Mustang enthusiasts after its original debut in 1969, and its reintroduction in 2003 brought new millennium updates and refinements. The modern-day version has the same bad boy shaker hood scoop, air dam and black rear deck spoiler. Also iconic are the side scoops and 17-inch alloy wheels that are similar to the original Mach 1 mags.

Merely the initial rumble of the modern-day V8 screams "hold on to your hat." With 45 horsepower more than the standard 4.6-liter Mustang engine, a quick blip of the throttle and our Torch Red test car quickly found its place in the fast moving traffic lanes. The 1969 Mach 1 could be powered by a 428-cubic-inch Cobra Jet V8, but the 2003 version uses an advanced dual-overhead cam 4.6-liter V8 (281-cubic-inch) engine that produces nearly the same horsepower (305 hp) as that monstrous 428.

http://www.edmunds.com/insideline/do/Drives/Followup/article...

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