Welcome to the North American Subaru Impreza Owners Club Wednesday August 20, 2014
Home Forums WikiNASIOC Products Store Modifications Upgrade Garage
NASIOC
Here you can view your subscribed threads, work with private messages and edit your profile and preferences Home Registration is free! Visit the NASIOC Store NASIOC Rules Search Find other members Frequently Asked Questions Calendar Archive NASIOC Upgrade Garage Logout
Go Back   NASIOC > NASIOC Technical > Built Motor Discussion

Welcome to NASIOC - The world's largest online community for Subaru enthusiasts!
Welcome to the NASIOC.com Subaru forum.

You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, free of charge, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join our community today!

If you have any problems with the registration process or your account login, please contact us.
* Registered users of the site do not see these ads.
Reply
 
Thread Tools Display Modes
Old 04-11-2009, 11:30 AM   #1
EJRex
Scooby Newbie
 
Member#: 119024
Join Date: Jul 2006
Chapter/Region: South East
Location: North AL
Vehicle:
2004 Impreza WRX
San Remo Red

Default Performance EJ20 Build - Project 205

Well after some debate whether to install the 2.5 or go a different route, I came across a hell of a deal on some STi and EJ205 parts.
I've always liked being the underdog/outcast, so I'm staying 2.0 for the time being. I've pushed the stock EJ205 to it's virtual limits, so now I'm going to see what the 205 can do when it's built.
This isn't a typical move for most, and info about the 205's potential when built isn't easy to find, so I'm going to build one.

First off, got a used 205 short block for 50 bucks. 30K miles, broke an oil ring, but never damaged the walls.. the cross-hatching is still visible, so the walls can just be honed/de-glazed and all's well.



Next I scored a set of used complete heads w/shimless buckets for 200 bucks. 27K miles, the owner had spun a rod bearing.



Then I got a deal on a set of slightly used STi cams for 150 bucks, from a wrecked 06 (these are hollow but in excellent shape).



So all that for 400 bucks.

Now for the goodies.. CP forged pistons, 8.5:1, with rings, wrist pins & locks, 500 bucks.





Cosworth Rod and Main Bearings, 170.



Full engine gasket set, 230.. Head bolts, 95.. Timing belt, 115.





No pics yet, but installing STi rods ($100 pull-offs) water pump (87 bucks) and oil pump (102) as well. I'm able to reuse my tensioner and crank pulley, and all accessories.
I won't be reusing the A/C system though.. I'll be removing all those components for weight reduction and less rotational mass.

Ok so add it up and you get 1799. Machine work will run approx 200, so we'll say 2000 for a complete, well built EJ205. I'll still be using the ported 20G, but may install the GT3076R kit I saved for the 2.5.
The labor will be done by me, so that's more I can save. I'll keep this thread posted with more stuff as I go... let's see what this little engine will do.
* Registered users of the site do not see these ads.
EJRex is offline   Reply With Quote
Old 04-11-2009, 12:24 PM   #2
stay_cold
Scooby Newbie
 
Member#: 187425
Join Date: Aug 2008
Chapter/Region: MAIC
Vehicle:
2007 VF39'd EWG'd
DPS tuned street machine

Default

Subscribed. I'm working on a similar project I wanna see your results
stay_cold is offline   Reply With Quote
Old 04-12-2009, 12:30 PM   #3
EJRex
Scooby Newbie
 
Member#: 119024
Join Date: Jul 2006
Chapter/Region: South East
Location: North AL
Vehicle:
2004 Impreza WRX
San Remo Red

Default

Some more photos of the build. WRX heads with STi cams. 3 angle valve job, resurfaced, slight port and bowl work, new valve guides, stem seals, locks and retainers.





AVCS holes in STi cams must be filled in/welded shut for use in non-AVCS EJ205 heads.



STi rods and CP pistons fitted, ringed, and ready to install.



Cylinders honed, standard bore.



Cosworth rod and mains installed.



Everything is going well, the heads and block are assembled and ready to install. Gotta set up a time to swap engines- should be by next weekend.. then a tune and back to the track for some drastically improved times, hopefully.
Will post more pics as I go.
EJRex is offline   Reply With Quote
Old 04-12-2009, 02:21 PM   #4
zeropsi
*** Banned ***
 
Member#: 175453
Join Date: Mar 2008
Chapter/Region: MWSOC
Location: wilCO, IL
Vehicle:
AE86 GT-S coupe
i <3 alqonquin homosauce

Default

Subscribing. Looks like a sweet build - may be following in very similar footsteps soon.
zeropsi is offline   Reply With Quote
Old 04-12-2009, 03:23 PM   #5
illmatic
Scooby Specialist
 
Member#: 3536
Join Date: Jan 2001
Chapter/Region: SCIC
Location: SD, OC
Vehicle:
2013 SWP BRZ Limited
2002/2003 AW/PSM WRX

Default

Nice build! What crank did you go with?

jay
illmatic is online now   Reply With Quote
Old 04-12-2009, 07:15 PM   #6
EJRex
Scooby Newbie
 
Member#: 119024
Join Date: Jul 2006
Chapter/Region: South East
Location: North AL
Vehicle:
2004 Impreza WRX
San Remo Red

Default

^ Well I'm not exactly sure.. it's a 2.0 crank, but is forged and has chamfered oil holes.. I assumed it's a 205 crank, but someone else said it was a 207.. but the engine is together now so I can't really go back and check it out..
EJRex is offline   Reply With Quote
Old 04-12-2009, 10:20 PM   #7
CKxx
Scooby Specialist
 
Member#: 33458
Join Date: Feb 2003
Chapter/Region: Tri-State
Location: PA
Vehicle:
Your BOV sounds lame
93 RX7+09 Forester

Default

Quote:
Originally Posted by EJRex View Post
^ Well I'm not exactly sure.. it's a 2.0 crank, but is forged and has chamfered oil holes.. I assumed it's a 205 crank, but someone else said it was a 207.. but the engine is together now so I can't really go back and check it out..
Either should be strong enough for quite a bit of HP, the difference, I suppose, would be to what RPM you can spin them and still have effective oiling.
CKxx is offline   Reply With Quote
Old 04-12-2009, 10:32 PM   #8
charliew
Scooby Specialist
 
Member#: 125304
Join Date: Sep 2006
Location: Crawford, TX.
Default

That looks like moly wheelbearing grease you used for assembly lube. Surely not.
charliew is offline   Reply With Quote
Old 04-13-2009, 12:17 PM   #9
b00stedPin0y
Scooby Newbie
 
Member#: 70977
Join Date: Sep 2004
Chapter/Region: SCIC
Location: Whittier
Vehicle:
2004 STI
Blue

Default

Very interesting thread, subscribed. Will be doing a similar build, very interested in how your will turn out.
b00stedPin0y is offline   Reply With Quote
Old 04-13-2009, 12:33 PM   #10
GDB FAN
Scooby Guru
 
Member#: 105814
Join Date: Jan 2006
Chapter/Region: NWIC
Vehicle:
two V8's..
'murica

Default

Quote:
Originally Posted by b00stedPin0y View Post
Very interesting thread, subscribed. Will be doing a similar build, very interested in how your will turn out.
+1

cant wait to see it finished.
GDB FAN is offline   Reply With Quote
Old 04-13-2009, 02:32 PM   #11
Homemade WRX
Scooby Guru
 
Member#: 33782
Join Date: Mar 2003
Chapter/Region: MAIC
Location: 3MI Racing LLC
Vehicle:
96 bastard child
search FIRST, then PM!!!

Default

for closing off the AVCS holes, an 10-32 tap, set screws and some lock-tite get the job done in a non-permanent (if you so choose) fashion

Also no worries of putting heat into the camshaft.
Homemade WRX is offline   Reply With Quote
Old 04-13-2009, 05:51 PM   #12
EJRex
Scooby Newbie
 
Member#: 119024
Join Date: Jul 2006
Chapter/Region: South East
Location: North AL
Vehicle:
2004 Impreza WRX
San Remo Red

Default

Quote:
Originally Posted by charliew View Post
That looks like moly wheelbearing grease you used for assembly lube. Surely not.
LOL noooooooo

It's assembly lube.. graphite I think.
EJRex is offline   Reply With Quote
Old 04-13-2009, 05:55 PM   #13
EJRex
Scooby Newbie
 
Member#: 119024
Join Date: Jul 2006
Chapter/Region: South East
Location: North AL
Vehicle:
2004 Impreza WRX
San Remo Red

Default

Quote:
Originally Posted by Homemade WRX View Post
for closing off the AVCS holes, an 10-32 tap, set screws and some lock-tite get the job done in a non-permanent (if you so choose) fashion

Also no worries of putting heat into the camshaft.
Good info.. I have heard of plugged holes leaking after a while though.. dunno if that was user error or the pressure is too great for those tiny plugs..
I didn't want to take a chance so I welded them. The MIG didn't heat up the cams much at all- took less than a minute to cool fully, and the holes are permanently closed (more for my peace of mind).
EJRex is offline   Reply With Quote
Old 04-13-2009, 06:36 PM   #14
Homemade WRX
Scooby Guru
 
Member#: 33782
Join Date: Mar 2003
Chapter/Region: MAIC
Location: 3MI Racing LLC
Vehicle:
96 bastard child
search FIRST, then PM!!!

Default

if you afriad of leaking lock-tite also makes another compound (can't recall its name/ Part#) that does well with liquid sealing for applications such as this.

Same stuff Darton sends out with their sleeves.
Homemade WRX is offline   Reply With Quote
Old 04-16-2009, 06:29 PM   #15
EJRex
Scooby Newbie
 
Member#: 119024
Join Date: Jul 2006
Chapter/Region: South East
Location: North AL
Vehicle:
2004 Impreza WRX
San Remo Red

Default

OK - finally got eveything together, torqued and taped, and ready for install this coming weekend. Some more pics for ya.

CP pistons installed.



Driver side head and valvecover installed. Installing cam seals.



AVCS holes MIG welded shut, and finished smooth. Very easy and quick job, and easy to smooth down with a small air sanding disc.



Finished longblock, ready for install. Oil and water pump will be installed when swapping accessories over.




Gonna try to install the enigine over the weekend, but we'll see how that goes. Will post some more pics later.
EJRex is offline   Reply With Quote
Old 04-16-2009, 09:44 PM   #16
LRZ03WRX
Scooby Newbie
 
Member#: 182377
Join Date: Jun 2008
Chapter/Region: Tri-State
Default

Very nice! I am excited to see how she runs. I have been undecided about doing a ej205 build, but this has peaked my interest. The STI rods bolt right it, no problems?
LRZ03WRX is offline   Reply With Quote
Old 04-16-2009, 09:48 PM   #17
kelley05
Scooby Newbie
 
Member#: 174596
Join Date: Mar 2008
Chapter/Region: South East
Location: Columbia SC
Vehicle:
2005 WRX
silver

Default

Quote:
Originally Posted by LRZ03WRX View Post
Very nice! I am excited to see how she runs. I have been undecided about doing a ej205 build, but this has peaked my interest. The STI rods bolt right it, no problems?

I have a very similar short block set up. The STI rods do indeed bolt right in with no issues. Im using stock STI rods in my ej205 short block. There a really good upgrade without the expense of aftermarket rods.
kelley05 is offline   Reply With Quote
Old 04-21-2009, 01:52 AM   #18
b00stedPin0y
Scooby Newbie
 
Member#: 70977
Join Date: Sep 2004
Chapter/Region: SCIC
Location: Whittier
Vehicle:
2004 STI
Blue

Default

Any updates on the build? really eager to see any progress.
b00stedPin0y is offline   Reply With Quote
Old 04-21-2009, 02:35 AM   #19
EJRex
Scooby Newbie
 
Member#: 119024
Join Date: Jul 2006
Chapter/Region: South East
Location: North AL
Vehicle:
2004 Impreza WRX
San Remo Red

Default

Had to postpone the install.. had some serious storms pass through this past weekend.. knocked out power for a while and made a mess of things around town, so I've gotta clean up a little bit and then I can get back to it.

I'll keep the thread posted as i go
EJRex is offline   Reply With Quote
Old 04-21-2009, 03:23 PM   #20
CoolRex
*** Banned ***
 
Member#: 85813
Join Date: Apr 2005
Chapter/Region: South East
Location: Myrtle Beach, SC
Vehicle:
2002 E46 M3
2006 RC51

Default

Subscribed to this one as well.
CoolRex is offline   Reply With Quote
Old 04-22-2009, 03:04 AM   #21
EJRex
Scooby Newbie
 
Member#: 119024
Join Date: Jul 2006
Chapter/Region: South East
Location: North AL
Vehicle:
2004 Impreza WRX
San Remo Red

Default

^ haha.. quit stalking me you psycho
EJRex is offline   Reply With Quote
Old 04-22-2009, 08:23 AM   #22
CoolRex
*** Banned ***
 
Member#: 85813
Join Date: Apr 2005
Chapter/Region: South East
Location: Myrtle Beach, SC
Vehicle:
2002 E46 M3
2006 RC51

Default

Haha
CoolRex is offline   Reply With Quote
Old 04-22-2009, 02:04 PM   #23
slowmike
Scooby Specialist
 
Member#: 24890
Join Date: Sep 2002
Chapter/Region: SCIC
Location: All I wanted was a Pepsi
Vehicle:
2002 Jackwagon
WRB GG

Default

Should be fun, what turbo?
slowmike is offline   Reply With Quote
Old 04-22-2009, 02:05 PM   #24
CoolRex
*** Banned ***
 
Member#: 85813
Join Date: Apr 2005
Chapter/Region: South East
Location: Myrtle Beach, SC
Vehicle:
2002 E46 M3
2006 RC51

Default

As he already posted....tdo6 20g
CoolRex is offline   Reply With Quote
Old 04-23-2009, 11:11 AM   #25
khellen9
Scooby Specialist
 
Member#: 66784
Join Date: Jul 2004
Chapter/Region: Tri-State
Location: Saylorsburg, PA
Vehicle:
2004 PSM WRX
18g & EWG'd

Default

Subscribed, I'd like to see how this turns out.
khellen9 is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
closed deck ej20 build problem illgod Built Motor Discussion 9 11-02-2007 05:42 PM
EJ20 build Scooby Rex Built Motor Discussion 3 07-26-2006 02:38 PM
NJ Legacy EJ20 Wagon Project Finished RUBEN Tri-State Area Forum 11 04-11-2006 05:47 AM
EJ20 build up WRX Ver.7 Factory 2.0L Turbo Powertrain 2 08-15-2002 09:46 AM
1995 Impreza EJ20 Rally project snwbrder206 Vancouver Impreza Club Forum -- VIC 4 12-09-2001 06:13 AM


All times are GMT -4. The time now is 12:37 PM.


Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Powered by Searchlight © 2014 Axivo Inc.
Copyright ©1999 - 2014, North American Subaru Impreza Owners Club, Inc.