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Old 12-28-2017, 09:04 PM   #1
righteous_fire
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Default FA20DIT Build Log

Long time lurker on NASIOC. I've posted a couple things, but have done most of my Subaru-ing off the forum.

I'm using this as a log for my FA20DIT build.

Plan:
Build a donor motor to hopefully be able to handle anything I can throw at it with a conservative amount of power.

Goal:
I don’t have a specific amount of power, but at least 300whp/350wtq would be plenty of fun. I’m not doing this for bragging rights or to be the biggest dog in the yard, but more so I can know that I won’t have to worry about blowing my motor.

Build:
- OEM FA20 case halves
- OEM Crank
- OEM Con Rod bearings
- King Main Bearings
- Manley Platinum 86.1mm (+.1mm) pistons
- Brian Crower Rods
- Killer B Oil Pickup
- OEM block and head botls
- TGV Deletes
- EGR Delete
- OEM Gasket and Seal kit

Mods:
- Accessport (of course)
- Crawford v3 AOS
- Grimmspeed EBCS
- Perrin Equal Length Header, Jet Hot 2500 Coated
- TurboXS catless J-pipe, fiberglass wrapped
- Magnaflow catback exhaust
- Mishimoto CAI
- TurboXS TMIC
- DW300c fuel pump
- Boomba BPV
- Mishimoto Oil Cooler
- Prosport Oil Pressure Gauge (w/ KillerB Oil Sender Adapter)
- ClutchMasters FX250
- RCE Yellow Springs
- ISC Lower Rear adjustable control arms

I will be assembling the motor myself, but will be utilizing local machine shops to do the honing, piston matching, cleaning, and possibly "blueprinting", unless I can a bore gauge and micrometer to borrow from someone.

So, on with it.


I had a 2004 STi in the past. Full bolt on, stock turbo, Delicious Tuning Flex Fuel (tuned by Bill) making 305whp/375wtq on E85. I ran E85 exclusively and it was a blast. My Ex spun it out one day and smacked a curb sideways, totaling the car , but I moved on to a VA chassis WRX in August of 2016.

https://imgur.com/XcNW1T3.jpg

2017 WRX Premium WRB

https://imgur.com/Sh5Po0B.jpg

You can see the STi shell in the background. I bought it back from the insurance company, and parted it out to the community so it could live on. I salvaged the calipers from the STi, had them sandblasted, cleaned them up, painted them, applied obligatory stickers (brembo), and using a bracket kit from KNSBrakes, some 08-14 STi rotors and stainless steel brake lines, I swapped my "meh" WRX brakes over to some Brembos. Much nicer now.

https://imgur.com/MNCtCMh.jpg

I got super lucky and someone from a local FB page had a donor FA20DIT they pulled from a totaled CVT WRX and were basically giving it away for $1,500, so I jumped on it immediately. It came with all accessories and looked to be of low mileage.

Life got in the way of plans, but within the past few months I started cracking away at the motor and getting it dissasembled.

https://i.imgur.com/k3xVOzt.jpg

So far I have the engine broken down to the short block minus the rods/pistons. I'm going to crack the case apart tomorrow, but so far everything looks like it's in great condition. I have no idea how many miles are on the engine, but it has a fair amount of carbon and deposits built up, but the bearings, journals, and cylinders look great.

https://i.imgur.com/d5hqpRB.jpg

I've already started receiving some parts.

https://i.imgur.com/sGMj8PW.jpg

https://i.imgur.com/3EivVZx.jpg

EDIT 29 Dec 2017:

Got the block split today, and everything looks fantastic. The journals on the crank are clean and the bearings show barely any wear. This motor looks as if it came from a very low mileage engine.

https://i.imgur.com/2VLs5OQ.jpg
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Last edited by righteous_fire; 12-29-2017 at 11:24 PM.
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Old 12-28-2017, 09:05 PM   #2
righteous_fire
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future stuff

Last edited by righteous_fire; 12-29-2017 at 11:25 PM.
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Old 12-28-2017, 09:06 PM   #3
righteous_fire
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placeholder

Last edited by righteous_fire; 12-28-2017 at 09:14 PM.
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Old 12-28-2017, 09:07 PM   #4
righteous_fire
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for the future
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Old 12-28-2017, 09:07 PM   #5
righteous_fire
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more to follow

Last edited by righteous_fire; 12-28-2017 at 09:25 PM.
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Old 12-28-2017, 09:11 PM   #6
Chuckable
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In for updates
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Old 12-28-2017, 10:12 PM   #7
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Watching closely.
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Old 12-29-2017, 12:59 AM   #8
dankor
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OP go on.....
give a rough date to all your work!
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Old 12-29-2017, 03:27 AM   #9
immortal
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Nice pickup on the motor, good deal.

This build thread should be in the member's gallery where everyone else does it though.
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Old 12-29-2017, 10:12 PM   #10
righteous_fire
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Quote:
Originally Posted by dankor View Post
OP go on.....
give a rough date to all your work!
Everything above was done in the past month or so. I'll date everything as it happens now, though. Most of my updates will be same day.
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Old 12-30-2017, 08:52 AM   #11
tramp
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Will you Magnaflux the crankshaft?
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Old 01-01-2018, 01:47 AM   #12
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I weighed all the pistons, wrist pins, and rods today.

The pistons weighed out at:

348.75g
348.63g
348.41g
348.79g

The wrist pins weighed:

96.58g
96.73g
96.63g
96.65g

The rods weighed in (including the bolts) at:

538.93g
538.95g
538.96g
538.82g

The paperwork that came with the rods states the weighed them with the Big End @ 386g and the reciprocating (pin) end @ 152g., but I don't have a rod balance to check it.

I would have liked the last rod to have an extra tenth of a gram on it, but it should be fine. I'm not building a race motor that going to be ran at its top end for significant periods of time, and in reality, any reciprocating mass on a horizontally opposed engine that's within 1-2g will be fine for the street.

I removed a bit of material on the inside edge of the wrist pin blocks to bring some of the pistons down in mass, and matched them with wrist pins to get the mass of each as close as possible to each other

348.75-348.57, matched with 96.58 - total 445.15
348.63-348.51, matched with 96.63 - total 445.14
348.41-nothing, matched with 96.73 - total 445.14
348.79-348.51, matched with 96.65 - total 445.16

Having all the piston/pin combos within a couple hundredths of each other is more than needed, but will give me added peace of mind knowing that one of the rods is just over a tenth of a gram heavier than the next. I may have someone balance the rods for me. Still on the fence about it.

I'm still waiting on a slew of OEM parts such as rod bearings, case and head bolts, gasket kit, and things like the clutch and whatnot.

I also need to call Element Tuning and see if Phil will mod my rocker arms only, without head work, to keep the pins from walking out.
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Old 01-01-2018, 01:49 AM   #13
righteous_fire
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Quote:
Originally Posted by tramp View Post
Will you Magnaflux the crankshaft?
Everything in my donor motor looks so pristine, I don't think I need to, but when I call the machine shop on tuesday, I'll see what they charge for it. Couldn't hurt, but I don't think it's necessary.
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Old 01-01-2018, 10:53 AM   #14
tramp
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'Fluxing the crankshaft should be $50 or so. Gonna balance? I know it has good primary balance but rocking couple..........
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Old 01-02-2018, 10:01 AM   #15
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Score on the used block. Good luck, have fun. Subbed
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Old 01-02-2018, 09:31 PM   #16
righteous_fire
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2 Jan 2018

Got the clutch today. Everything looks good there.

Dropped the block, heads, crank, pistons, and rods off at the machine shop. They are going to clean everything up, polish the journals, balance the rods (I already weighed the pistons to within a couple hundredths of a gram of each other), and they said they will do a 3 angle valve job while they are in there, because it's going to cost the same to have it done, or not, so I figure, what the hell.

I also started a YouTube channel for this process, as well as any other car shenanigans and projects I get into.

Please take a look at the first video.




Thanks for taking an interest!
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Old 01-02-2018, 09:52 PM   #17
righteous_fire
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Quote:
Originally Posted by tramp View Post
'Fluxing the crankshaft should be $50 or so. Gonna balance? I know it has good primary balance but rocking couple..........
4 cylinder Boxers have good primary and secondary balance, but you cannot completely eliminate rocking couple due to the design of a horizontally opposed engine. You can "manage" it by changing the design of the crankshaft, or adding balance shafts, for instance, but Subaru's solution to this problem is to have rather thick main bearing couplers.
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Old 01-02-2018, 10:30 PM   #18
tramp
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Rocking couple is neither first nor second order imbalance. It's a torsional vibration best dealt with by a good dynamic balance and harmonic damper a la Fluidamper.
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Old 01-02-2018, 11:10 PM   #19
righteous_fire
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Quote:
Originally Posted by tramp View Post
Rocking couple is neither first nor second order imbalance. It's a torsional vibration best dealt with by a good dynamic balance and harmonic damper a la Fluidamper.
I know that. I was expounding on your primary balance comment.

Rocking couple is a rotational torque caused by the inherent design of the motor. It cannot be eliminated in a boxer engine, but as I said, it can be managed.
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Old 01-13-2018, 03:21 AM   #20
righteous_fire
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Everything is back from the machine shop. Piston to Cylinder clearance set to .0035" as recommended by Manley for "high boost" which is 25+lbs. I'll probably be peaking around 24 on the stock turbo, and averaging around 21-22.

Piston rings have been gapped and filed to at least .020" for both top and second ring, again per Manley's instructions.

Everything has been brought in from the garage to bring it all up to building temp (room temp is approx 73F at the moment. It will cool slightly through the night for tomorrow morning.

I'm planning on assembling the shortblock tomorrow, and adding the heads sunday.

https://i.imgur.com/XnMbMpE.jpg
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Old 01-16-2018, 12:00 PM   #21
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Is that you Vinnie? Just stumbled on this thread while I'm at work and saw the familiar pictures. This is Lan btw
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Old 01-16-2018, 03:49 PM   #22
righteous_fire
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Quote:
Originally Posted by verdalix View Post
Is that you Vinnie? Just stumbled on this thread while I'm at work and saw the familiar pictures. This is Lan btw
Ha, yeah it's me.
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Old 01-16-2018, 04:15 PM   #23
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Quote:
Originally Posted by righteous_fire View Post
Ha, yeah it's me.
I smell a subaromance
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Old 01-17-2018, 12:09 AM   #24
righteous_fire
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Quote:
Originally Posted by noobultimatum View Post
I smell a subaromance
He's a local Subie-head in my area.
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Old 06-14-2018, 11:38 AM   #25
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cool any updoots?
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