2.35 Build

[raijin]

I thought I would start a thread to track progress with my 2.35 build.

I managed to pick up a set of EJ22T casings from a farmer in the USA (these are rare as hen\'s teeth now!).

Rear thrust conversion complete, surface ground and bores honed to suit pistons.

All ready to receive an EJ257 crankshaft

Pauter X-beam conrods (these are built to last!)

Mahle 2618 stroker pistons matched to bore

The crowns and skirt are coated as standard

Check out the design - these pistons really are a work of art

There is even a cut out to clear the oil squirters - no need to get out the die grinder

I\'m currently in the process of chambering a pair of JDM big port AVCS heads to match the 98 mm bore 8)

[lachlan]

shit those pistons nearly resemble a mx bike piston . 8)

i was tempted with doing this , however i was goin to stay short stroke . but maybe the same pistons with long rods

[raijin]

Hi Lachlan what casings are you running?

I think the pin height on these pistons has been set for the standard length rods on a 79mm crank so doubt they would work with a longer rod.

[Koom]

 raijin']

Hi Lachlan what casings are you running?

I think the pin height on these pistons has been set for the standard length rods on a 79mm crank so doubt they would work with a longer rod.

With a 75mm crank and stroker pistons, you can fit longer rods. Which is what it sounds like he was thinking of doing. Have had similar thoughts myself in the past.

[quote name='lachlan said:

s*** those pistons nearly resemble a mx bike piston . 8)

The waisted design of the underside is very sexy!

I didn\'t want to hide mine inside the block.

[Subirex Automotive]

that block looks mean Allister. keep us updated.

[raijin]

"With a 75mm crank and stroker pistons, you can fit longer rods. Which is what it sounds like he was thinking of doing. Have had similar thoughts myself in the past."

Ah I see - have you run calcs on potential impact on torque of this configuration?

[lachlan]

people rave about the 2.35 aswell . so dont let us upset you .

my research lead me to a few respected egine builders saying "big bore ,short stroke and long rods " was the way to go

i see a 2.35 as a de bored ej25

where as a 2.2 is a big bore ej20 . which id prefer . but horses for courses ,people love both .

id rather have a higher red line and a 5000 rpm power band from 3-8 k rpm etc

i was going to jb weld a na 2.2 block ala http://www.clubsub.org.nz/forum/index.php?topic=31696.0;wap2

[raijin]

 lachlan said:

people rave about the 2.35 aswell . so dont let us upset you .

my research lead me to a few respected egine builders saying "big bore ,short stroke and long rods " was the way to go

i see a 2.35 as a de bored ej25

where as a 2.2 is a big bore ej20 . which id prefer . but horses for courses ,people love both .

id rather have a higher red line and a 5000 rpm power band from 3-8 k rpm etc

i was going to jb weld a na 2.2 block ala http://www.clubsub.org.nz/forum/index.php?topic=31696.0;wap2

That\'s certainly an innovative approach to closing the deck. In know a chap who welded a deck closed with TIG but it ended up distorting the bores excessively unfortunately.

I\'ve previously run a 2.1 CDB stroker so did consider just running the EJ22T as a 2.2 out of curiousity to see any difference in rev response and torque output between the two set ups. Horses for courses as you say. 8)

[lachlan]

i am jealous of your a 22t block , did you pay a premium for it ? or was it a bit of a lucky find ?

yeah the jb weld is interesting . did also consider smacking short bits of alloy dowel in all the way round it too

[Roo]

 lachlan said:

people rave about the 2.35 aswell . so dont let us upset you .

my research lead me to a few respected egine builders saying "big bore ,short stroke and long rods " was the way to go

i see a 2.35 as a de bored ej25

where as a 2.2 is a big bore ej20 . which id prefer . but horses for courses ,people love both .

id rather have a higher red line and a 5000 rpm power band from 3-8 k rpm etc

i was going to jb weld a na 2.2 block ala http://www.clubsub.org.nz/forum/index.php?topic=31696.0;wap2

a longer rod and shorter stroke is making it more efficient at higher revs.

High rpm efficiency = high rpm power

High rpm power = bedy nice

[zeroyon223]

Cool build, subscribed! Close deck ej22 is from legacy usa turbo?

JB weld close deck? Wow any photos? Isn\'t devcon a lot stronger than JB?

Pistons looks nice, mahle do a 2618 and 4032 lower expansion, are the 4032 not strong enough for this build?

[lachlan]

yeah gotta close them rods up .

ugh the whole naisoc thread reeks of missing the point . specially when he have the results on here already .

zeroyon i already posted the cs link

lol yeah the US got a closed deck ej22t . but it didnt even have an intercooler . had a butt ugly pipe straight from turbo to T/b

[raijin]

 lachlan said:

i am jealous of your a 22t block , did you pay a premium for it ? or was it a bit of a lucky find ?

yeah the jb weld is interesting . did also consider smacking short bits of alloy dowel in all the way round it too

I\'ve been on the hunt for a pair of these since 2010 and it was a lucky find. They came out of a USDM legacy which was a farm run around in the midwest in the states and was being broken for spares so I did not pay a silly premium.

[raijin]

 zeroyon223 said:

Cool build, subscribed! Close deck ej22 is from legacy usa turbo?

JB weld close deck? Wow any photos? Isn\'t devcon a lot stronger than JB?

Pistons looks nice, mahle do a 2618 and 4032 lower expansion, are the 4032 not strong enough for this build?

yes these are 2618 alloy which has higher expansion than 4032 so you need to run a little more clearance. This makes them noisier when cold but they can take a serious spanking ;D

[lachlan]

apoligies here is correct jb weld thread

http://www.clubsub.org.nz/forum/index.php/topic,31696.0.html

[Koom]

 raijin said:

"With a 75mm crank and stroker pistons, you can fit longer rods. Which is what it sounds like he was thinking of doing. Have had similar thoughts myself in the past."

Ah I see - have you run calcs on potential impact on torque of this configuration?

I just went back and searched through my old spreadsheet I made to analyse the difference\'s in the geometry of a bunch of engines and possible hybrid setups.

Longrod EJ20 doesn\'t make 2/3rd\'s of F all difference on paper (from a normal EJ20) but I was always more interested in doing it if building another 2.0L as it just required custom length rods and the rest of the stuff was off the shelf.

But then I went halfway and built a 2.1 stroker but with slightly longer rods so the geometry isn\'t far off a normal EJ20\'s rod/stroke ratio in the hope that it\'ll still be ok at higher rev\'s. Still waiting on the motivation to get it finished and on the dyno to find out if my theorising was right or not.

[raijin]

thanks - here\'s a 2.1 stroker from one of the leading subaru specialists in the UK holding power very nicely at higher rpm (can\'t see the exact rpm but you get the jist from the shape of the power curve). Torque curve is flatter with a 2.35.

Standard length rods with a 79mm crank and even using the OEM JDM AVCS cams on this application (with supertech valves and springs). 634 bhp on 99 octane pump fuel using a Gt3582 billet @2.1 bar iirc.

http://i1217.photobucket.com/albums/dd391/AdvancedAutomotivescom/Escort%20mk2/Graphs/AFRatiovsPower-1.jpg?t=1335030238

[nismovzr2003]

Unsure if its even worth it, but is it possible to bore out a 2L CDB to except 98mm pistons as used in this build with the 2.2L CDB?

I\'m currently running a 2.1 Stroker CDB using standard 92mm Mahle Pistons, Custom Molnar Rod\'s and a late model Legacy 2.5L rear thrust crank, just wondered if the block would except bigger pistons and still be strong enough?

[raijin]

 nismovzr2003 said:

Unsure if its even worth it, but is it possible to bore out a 2L CDB to except 98mm pistons as used in this build with the 2.2L CDB?

I\'m currently running a 2.1 Stroker CDB using standard 92mm Mahle Pistons, Custom Molnar Rod\'s and a late model Legacy 2.5L rear thrust crank, just wondered if the block would except bigger pistons and still be strong enough?

Yes you can but you need to insert liners so there is significant machine work and cost involved. I had a 2.0 CDB modified to receive dry westood liners to run a 98mm bore. One of the liners dropped a couple of thou after running circa 2 bar boost though so I had to strip the motor and have the casing redecked which was a pain. That\'s when I decided to go down the EJ22T route to rule out potential future liner related issues.

[rex-leggy]

ive done simlar . put darton sleves in a 2l cdb to suit 98mm pistons.

but sleves shouldn\'t drop if machined and installed correctly. they shouldn\'t be able to drop at all

[nismovzr2003]

I haven\'t had my 2.1L Stroker CDB block tuned as yet, so I\'m a little unsure of what it might be cabable of or its reliability.

As stated, its running 92mm Mahle Pistons, custom Molnar Rods (which are slightly longer than standard from what I\'m told), late model Legacy 2.5L rear thrust crank.

Running v3/v4 Sti Heads with Kelford 268/264 cam\'s and adjustable cam gears. Link G4 (plus 4Bar MAP sensor), Garrett GT3082R turbo, Tial 44mm wastegate, 800cc injectors, etc.

Will be interesting to see how it all goes

[nismovzr2003]

 rex-leggy said:

ive done simlar . put darton sleves in a 2l cdb to suit 98mm pistons.

but sleves shouldn\'t drop if machined and installed correctly. they shouldn\'t be able to drop at all

How much did this cost?

[rex-leggy]

liners were around 400. hard to tell how much the liner install was tho as I got alot of other stuff done also .

[raijin]

 rex-leggy said:

liners were around 400. hard to tell how much the liner install was tho as I got alot of other stuff done also .

Are they top hats?

[rex-leggy]

? its a complete liner or sleve

http://realstreetperformance.com/Shop-by-Engine/Sleeves_29/Darton-Dry-Sleeves-Subaru-EJ257-Impreza-Sti-2-5L.html