Andrew & Tamra's 818SR EM Autox Hybrid Destroked Long-Rod Build

[Tamra]

We brought our 818 home today! We've kept a donor thread here for the full teardown process, but now that it's time to start assembly, we figured we should create a build thread. Our 818 is #297.

Our excited faces:


We ordered a white body:


As one of our friends put it, "the 818 is definitely the better move"



We have never owned Subarus before (Mazda family), and we've definitely never built a car before. Let alone a motor. This will be a learning process. Our goal is to autocross our 818 and also have it be street legal. Our hope is to have it on the road next spring.

We are going to build a 2.34L destroked short block, built for up to 650whp, but we will be tuning it to around 350whp max, with multiple maps. The machined 2.0 Heads will have an upgraded valve train. Oiling will be our limiting factor, so we will be running it at 8k rpm max to start. We are still deciding on the turbo, but leaning toward a BW 200SX twin scroll setup.

We will be doing all of the assembly of our engine. Larry's Power did the machine work on the heads and block and balanced the rotating assembly. We balanced the rods and pistons ourselves to .1 grams. We purchased our parts through Fidelis Motorsports, who also helped us pick the right parts for our goals.

Updated list of parts 9/1/15
2.34L destroked short block
-MPS +2mm H Tuff rods
-JE FSR Pistons
-upgraded Tool Steel Wrist Pins
-75mm WRX cross drilled crank
-King Race and Main Bearings
-ARP Subaru EJ Series DOHC Headstuds

2.0 Chamber Matched Machined Heads
-Shimless buckets
-GSC Beehive Valve Springs w/ Titanium Retainer Valvetrain Kit
-GSC Chrome Polished Intake Valve
-GSC Chrome Polished Exhaust

Turbo Setup
Borg Warner S200SX 51mm .84 a/r twin scroll turbo
Kinuguwa Twin Scroll Header (sits level with the oil pan!)
Custom twin scroll up-pipe, fully divided into divided T4
Two Tial 38mm EWG's, fully divided and plumbed back into exhaust


Supporting mods:
Speed Density with AEM 3-Bar and post intercooler temperature
Injector Dynamics Fuel Injectors 1000cc
Partial TGV deletes
Forge bpv
Grimmspeed ebcs
DW 300lph fuel pump
STI oil pan
Killer B Motorsport Ultimate Oil Pickup
Killer B Motorsport Oil Baffle Windage Tray
New OEM 11mm oil pump, 4 shims
Cobb intake
NGK 1-step colder plugs
Semi-parallel fuel lines
Gates Racing Timing Belt
Group N engine and transmission mounts
Frozenboost AWIC with upgraded Bosch pump


Other items:
ACT StreetLite Flywheel
South Bend Stage 2 Endurance Clutch
OBX LSD (upgraded washers/bolts)
FFR adjustable lateral links
Aluminum control arms for the "castor mod" with 4mm spacers
Stainless steel braided brake lines
Custom sway bar TBD
Koni 30 series shocks with 500lb springs in front (R package)
Race seats - Sparco Corsa
15" and 16" wheels with Hoosier A6/A7's
Prosport Gauges with alarms
Custom shifter routed with cables going straight back
Schroth Profi II ASM FE harnesses with sub straps (DOT approved 5 point)
The car IS street legal and registered

Other project creep TBD


We have very limited space (two 10x20ft garages, one which is fully taken by the Miata and the bike), so when we got it home, first thing was to hang the body panels from the ceiling of our second garage. The bumpers and fender didn't fit, but at least most of them are out of the way.


All tucked away:


At this point, all of our donor parts have been cleaned and painted, bushings replaced where necessary, etc. The wiring harness has had a once through and had everything unnecessary deleted, although we haven't re-routed anything yet. The transmission has an OBX lsd installed with the upgraded washers. We are still in process of building the motor, so that is one of the primary items on our list for this week, in addition to taking inventory. The only items on the packing list that were backordered were small items that we will not need for awhile.

Thanks to all of the threads on this forum, we have already learned a great deal. As you read through our posts, please feel free to comment if you see any issues or have any recommendations.

Also, my better (or at least more mechanical) half is Andrew, forum name xxguitarist.