Lets get this build rolling!
After a plan was formed that it would become a "rod only" development build I wanted to keep the modifications on the engine semi light so they could easily be repeated for a customer build in the future. So the formula was simple
- Forged Conrods
- Used stock pistons with the top ring gap opened up so it doesn't butt ends under higher cylinder pressures.
- Some very light work on the combustion chamber and piston crowns to improve det resistance as compression was staying high but no other head work to keep labour costs down.
- Kelford valve springs to better cope with higher boost pressures and I was using early pre 2015 heads which had a recall out on the valve springs anyway!
- Cosworth 1.45mm thick head gaskets to drop the compression ratio from 12.5:1 to 11.6:1
- Extensive rework of the internal oiling channels, front cover, oil pump cover, lower sump half, larger pickup pipe with the strainer moved to the bottom of the sump pan but retaining the stock oil pump gears
- Fluidampr crankshaft pulley - I wanted to couple this with a stock flywheel to create a very smooth engine that helps with driving in heavy traffic as well as controlling crankshaft vibrations at high loads and high rpm
- OEM Toyota/Subaru crankshaft main bearings and conrod bearings. I did want to use king bearings here but at the time they were unfortunately on back order and I couldn't get hold of them in time.
Total cost of parts as of 05/05/2020 if you wanted to copy the build was £2314.04 very reasonable when you consider a fully forged engine build will cost considerably more on parts and machining. The machining of these blocks for forged pistons has a very chequered history also with a LOT of these engines being left as worn out oil burners in a very very short amount of time.
I bought the car from Adrian without the engine and the deal included free reign of used engine parts we had in stock, awesome! That covered everything except a block as we had no good case halfs in stock. So brand new case halfs were ordered from Toyota which arrived in only a couple of days
The hateful job of stripping the sealer off the used parts began. For those of you who don't know the head gaskets are the only real gaskets in the engine. Everything else that has 2 flat services is sealed with a sealant. The sealant Toyota/Subaru uses cannot be easily removed with any chemicals, it takes a lot of time with a blade, plastic "wire" wheels on a drill, parts washers and most importantly time time and more time. When you have one of these built the largest portion of your labour bill comes from removing sealant!
Changing the valve springs
Lets get the rest of it put together!
It is finally ready to go back in the car! Stay tuned for more.