yes it's getting there kev and have more things on the way plus im hoping that CDF RACING can get some fuel rails up and made so i can see what they are like

also a big part of parts have came from ADVANCED AUTO PERFORMANCE PARTS which is located in bristol and are in association with roger clark motorsport and have been very helpfull and supply almost any parts/ tunning parts you can think of and are willing to go that extra mile to help and seem to know alot about imprezas and fords eg cosworth plus they have machine shop ect..

soon as i can get five mins will get some more done

 

Big steps forward there Lee..... will you be at the meet next week by chance ?

 

don't know if i will be at the meet yet but will try as for going farward a few more bits have came
arp head studs, new valve stem oil seals, and camshaft seals plus set of cometic head gaskets

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before sending my heads to be checked i have started porting heads

first scribed where exhaust gasket sits to open it up

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then took some picks in stages but this still aint finished as i run out of sanding flaps and grinding stones so will get some in the morning then it will be ready to polish after little mere work

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also done some work on the inlet side but still need to do a bit more to finish but as said run out of sanding drums
will not be polishing the inlet side it was more of just remove casting marks and dimples plus there is a ruff part just to the rear of the seat which i smoothed , i also started to thin or knife edge the devider in the middle but as said need to spend a little more time on the finish soon as i get new bits

pic of the ruff inlet

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pic smoothed

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pick of both exhaust and inlet smoothed

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inlet port smoothed and semi knife edged

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it has taken a good few hours just to get to this point with one so to get them all done and finished will take a long time plus its not as easy as it looks to do but the pics are not of them finished and will get pics of them when all done

 

I will be bringing a few bits along for you that you may find handy for fettling, if your not there who can I pass them onto ?

 

Unfortunately the gasket on the exhaust post should not be used as a reference for porting except to centre the hole. The size of the exit is already the correct size, a good match for the inlet of tubular headers, and needs little or no enlarging.

You can get away with it if you have heavily ported cast headers, but tubular headers will cause a problem as the tube is typically 38mm bore.

 

thing is my mate makes stainless steel exhausts for a living and is making me a set off headers which will match the same size as these ports, so i dont need to worry about standard tubular headers, as he has all the tools and machines too get every thing matched up and perfect...

just out off curiousity if i was too buy gt spec headers wouldnt i of been able to open the flanges slightly by coneing them to match the ports if they were slightly smallier??

 

You would be able to open up the flanged area a little, but IMHO you have made a slight error. On the whole thought I don't think it will adversely affect it a great deal. Standard sized exhaust ports seem fine with considerable amounts of power.

You do NOT want to make headers that have primary tubes the same size as the gasket hole.

 

so if i did go for gt spec or similar, it would be better to enlarge the flange than to have my mate make me headers of same size ???

 

PM sent.

 

pm'ed back

 

don't know if anyone can advise me but was just thinking i have 1.6 cometic gaskets but would i need a different size if the heads needed a skim or would they be ok to use if only a certain amount came off if they needed skimming ( heads have never been skimmed before )

 

Depends on pistons and head combo. If you bottom end is together, get the pistons to TDC and measure the deck height, ie the distance the piston is below the top of the block or above it. Check all 4 pistons as they do vary.

On EJ257 pistons you often find they are below the deck by around 0.4mm, in which case 1.6mm gasket is on the thick side from a squish point of view. However depending on the piston dish and head volume you're CR will be in the low 8s.

A nominal skim on the heads will still leave them with about 46cc volume, so you need to add the gasket volume the deck height volume (which will be a negative number if it's above the block) and the piston dish volume (should be on the box the pistons came in). From there you can work out your CR.

For deck height of 0.4mm, 1.6 mm gasket and 22cc piston dish

CR= (CCV+CV)/CCV

Cylinder volume is 614.275 cc
Piston dish eg 22cc
Deck volume is 3.11cc
Gasket volume is 12.81cc
Head volume 46cc
Total CCV is 83.92

CR = (614.28+83.92)/83.92 = 8.319

So the above example shows that you should be in the ball park, and the thicker gasket will certainly result in a closer to stock cam timing. But would give a squish of 2mm which is next to pointless. So you may find that a thinner gasket would not adversley affect likelyhood of det despite increased CR, but I would be wary of trying a 9:1 CR if you want to run a big turbo and aim for 500hp on pump fuel.

 

What he said

 

cheers pavlo as for the heads one is done now and the other is almost there just a few more hours more on it after they are done will be building heads back up but first a bit of a garage clear up then will be starting to fit my 6 speed gear box with only 20,000 on it it's a uk box and came with rear diff but no linkage or shaft but i have ordered these and should be here any day now so thats the next job after heads are done

 

Great thread mate keep the pics comming if only i new half the stuff u did.

 

Great work Lee, keep it going bud

 

cheers guys haven't done much in the last week but managed to get the heads skimmed and got them today also managed to start cleaning the valves and will be lapping them in the next day or so then will be building them back and then it's on to fitting them to the block
anyone know what spec the under bucket shims should be between?? and cam clearence? any help would be great as i can't seem to fined any specs for the sti under bucket and can only fined wrx top shim specs

 

same clearances

 

cheers fella

 

right guys done some bits Wednesday managed to clean heads and lap valves in one of them and also started to cleen up the cam wheels

before and after of cam wheel will get a photo of all 4 when finished

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some of heads but camera is not the best and dose not do them justice as its only a 4 meg pixel

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and today managed to get the other head lapped and then put together and managed to get one fitted on the short block with the arp rod bolts and cometic gasket
only thing is i forgot to take pics of the build as i forgot all about the camera in the excitement of fitting them today
fitted the rod bolts and cleaned everything then followed manual on fitting them sorry never got pics guy but will get some of them on the block asap and will try not to forget i again

 

sorry guys didn't know but posted under my other halfs name as she was signed in

 

Looking good Lee!, your be back on the road in no time mate

 

Nice bit of cleaning there Lee

 

i know simb, im way ahead of where i thought i would have been

 

they come up well with the right tools for the job

 

Looking good Lee Keep up the good work bud

 

cheers fella
heads are on and all clearences with shims are correct and spot on and cams are now on too next job is to clean the rest of the cam wheels up
i was going to paint the rocker chest covers blue but after i cleaned them up i thought i like them as they are
i will get some pics of the engine with heads on asap but will just show the gaskets which cost a small fortune as i did not want to get non original gaskets as i have used al original from start
and quick pic of the chest covers clean and can't wait till my new sump with baffel plate arrives as its almost been a week but i blame the weather will get pics when it arrives

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That's the way to do it looking good there Lee, it's all in the detail buddy

 

finished off cam wheels and pic of them on engine

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looked at the idle pulleys and the toothed one and bottom one has play in them so have ordered new so hopefully will be here in a day or so and phoned about my new sump with baffle plate and should be here hopefully tomorrow
when idlers arrive i will put my old belt on as it's an original subaru belt and only changed it a month or so before it went pop

thinking of putting middle belt cover on and leaving the sides off anyone know if this would be ok or other option would be to cut holes in the outer covers to see pulleys just want it to look abit different

 

This thread has to be the best one on SN! Keep it up matey. When do you anticipate it all being done?