New Heads & Intake

[CLS447]

We took the stock heads of the 81 & will reinstall the dual port heads today.

Hope to post finished pics tonight.

Here are some with the heads off.

[Butch S.]

What cam?
Butch

[barnstorm2]

what kink of HP are you expecting?

[automan1223]

I wondered when you were going to do that..

curious how it turns out.

Jonathan

[Rehan K.Janjua]

Hello Chris

Good Move. Best of luck
Do let us know how it feels.

Regards.
Rehan Janjua
Air Command. Pakistan

[CLS447]

Ok, it went well yesterday, First thing we did was to retorque the head studs to 10 ft lbs., that made the studs more even in length than what they had been.
The center studs had come out when I had removed the old heads.

After cleaning the gasket surfaces, on went the new gaskets,heads, & rocker assemblies. Final torque....47 ft lbs.

Then we fit up the intake. Couple of things to overcome.... Alternator mount brace... the bolt hole is removed from the heads when converting the heads to dual port. Need to remake brace to reach the other hole!

Spark plugs are a little more difficult to access... no big deal.

When we started running the engine a couple years ago.. I did not think about retorqueing the heads, & we ended up with slight coolant leaks & lots of coolant overflow. After retorqueing, it stopped the overflow but we still had a little seepage at the gaskets.

This time , after running up to temp, we will cool & retorque immediately!
But now the intake will have to come off to access the head bolts....more fun!

The carb must be rotated 90 degrees for the new intake....redo throttle cable, choke cable, carb heat cable, & fuel line......Yaaaaaa!

Also a little mod to the coolant lines & air filter assembly & she will be ready to fire up after I reset the valve clearances. Oh, also have to put my shorty exhausts back on until the new one is made.

Before we started teardown, we tied the machine down & repitched the prop fpr 5000 max rpm( 13 degrees on the 68" Warp ).

With the new heads & intake we will check for rpm increase. If not very dramatic it may be time for plan B......EJ22 or 25 !!! Possibly selling this EA81 for the funding.


Butch... I have the cam specs from Joe Souza. I don't know who did it but RAM says it sounds like a good one. I really don't want to crack the engine & mess with the cam right now but if it shows enough promise, a whole bottom end job might be in order.( pinned cases, forged pistons, better cam, if there is one, etc.)

Tim....have you been to Rams website? He claims with his engines that 140hp is a reality. So my reality would like to see 120? I would try a supercharger if the price was right & it would fit up easily!

[ben]

ssswwwwwwwwwwwwweeeeeeeeeeeeet

[Phil_Ruffin]

Chris, Chris, Chris,,,,,,, I am completely beside myself. I thought you had more self respect for yourself than this.

To post photos of your work and not put the effort into making sure that everything is on the up and up.

When I looked at the photos I was embarrassed for you when I saw it, yes Sir, there it is, a little smug on a motor mount bolt.

Geeezzzz Man, you gotta do better! :D

[StanFoster]

Chris: Snazzy.......cant wait to see you flying...

Stan

[CLS447]

Thanks Stan, I've got my fingers crossed!

Phil, thanks for pointing that out, I can't wait to go get a look at that in person. I promise to get rid of that nylock right away!

It may just be an oil smudge that needs to be wiped off. There is a nasty little leak coming from the pan & it is in that area.

We already replaced the gasket on the pan once & it did not take care of it.

The next time will be the last as I will just have to trash the whole gyro & buy a cessna.......yeah right!

[Aussie_Paul]

140 hp?? Wow!! BUT for how long??? The Sub4s don't seem to be able to hack the reliability scenario. The old compromise thing again. HP and relaibility. I seems to be difficult to get both out of the ea-81 even though they are a beaut little engine.

It seems looking from the outside that 100 reliable HP is achievable, and after that you just wait for the "bomb" to go off!!!!

I am afraid that I have had so much success with the ej-series that I don't really want to experiment with getting 140 hp out of the ea-81. I don't like walking home!!!!!

Aussie Paul. :)

[Screw]

Screw-In

Looks Great Chris! Keep up the good work and tell Shar I said hi!

Screw-Out

[david holmes]

Chris,
is that red hose for water?
if so, where did you get them?

[Dean_Dolph]

140 hp?? Wow!! BUT for how long??? The Sub4s don't seem to be able to hack the reliability scenario........Aussie Paul. :)Paul, what type of failures are occurring? Are they major component failures with crank/rods/pistons/heads or where?

Some component failures are the fault of the application/installation while others are inherent because an engine was not designed for the service/power. If it is an inherent engine problem then there is not much that can be done. I don't follow the hot rod scene as close as I once did but still keep tabs on what is going on and to date I don't get the feeling that the Sub is anything but bullet proof. But that is a general feeling and not an EA81 specific one. I suspect that Jonathan Weis, aka Automan 1223, has a closer view of the street situation.

[GyroRon]

I hope it works out for Chris. It would suck donkey balls to have spent so much time and money to try to make this EA-81 fly two people and then have to pull it off and spend all that money over on a EJ-22.

I really don't think Subarus were designed to be used like we use them to fly. Taking a engine that put out 70-80 horsepower and hotrodding it to 120-140 horsepower is almost doubling the output. Doing this for short spurts such as drag racing or just for having a cool car and doing burnouts to impress your friend is one thing. To do this to a engine that is going to need to produce that much power steadily for hours on end is another. I personally think this engine will not hold together if Chris pumps it up to the level needed to fly two heavy people.

[CLS447]

Dave, I got mine from coolflex.com . Check them out. They were pretty expensive & others have gotten them for alot less on ebay & from other suppliers.

I don't know if they are of the same quality but shop around a little & you will do fine but check out the coolflex website first.

I've gotta go to work again today(Sunday) but we'll continue the EA81 debate later.All I can say is let's wait & see how it works out for me.

If I knew then what I know now, I would have went with the EJ engine.

We all learn from our mistakes but it is cheaper to learn from others.

I still have faith!

[Aussie_Paul]

I hope it works out for Chris. It would suck donkey balls to have spent so much time and money to try to make this EA-81 fly two people and then have to pull it off and spend all that money over on a EJ-22.

I really don't think Subarus were designed to be used like we use them to fly. Taking a engine that put out 70-80 horsepower and hotrodding it to 120-140 horsepower is almost doubling the output. Doing this for short spurts such as drag racing or just for having a cool car and doing burnouts to impress your friend is one thing. To do this to a engine that is going to need to produce that much power steadily for hours on end is another. I personally think this engine will not hold together if Chris pumps it up to the level needed to fly two heavy people.

That is the trouble Ron. The ea'81 is a wonderful little engine and quite a few have flown 2 people training in oz. BUT they were approx 100 hp and a bit marginal BUT again marginal was what all us old timers were happy with!!!

People complain that the ej series is heavier, some say too heavy!!! Why??? We are lucky with our gyroplanes, as compared to fixed wing aircraft. We can just add a foot or two to our rotor diameter. I have flown quite sporty Rafs with ej-22s straight out of the wrecker’s yards that had done around the 70k miles.

Over the years I have had a couple of wreckers specifically looking for suitable wrecked cars from the rear or side. When they happen to get one that they know will suit me they ring, and I buy and sit them in the shed until I needed them.

I am now dealing in new ej-20 (134 hp)and 25 (167) SOHC engines. Gee they are nice when they are new or less than 20k miles.

I sincerely hope it works out for you Chris. I would rather a marginal reliable machine, than a hot dog one waiting for the right time to quit, BUT that is only me!!

Aussie Paul. :)

[MikeBoyette]

Chris,
Dad really likes the ej 20 he put John Palmer's machine. He said the next two place he builds will have that engine on it.
Paul,
Dad got his ej20 from Neil in New Zealand. It came with a fancy computer that makes the engine run real well. He said he was getting 140 hp. The machine was identical to his Sub4 machine and it would blow the Sub4 away. I think the ej20 is lighter than the ej22, with about the same hp.

[Aussie_Paul]

Chris,
Dad really likes the ej 20 he put John Palmer's machine. He said the next two place he builds will have that engine on it.
Paul,
Dad got his ej20 from Neil in New Zealand. It came with a fancy computer that makes the engine run real well. He said he was getting 140 hp. The machine was identical to his Sub4 machine and it would blow the Sub4 away. I think the ej20 is ligter than the ej22, with about the same hp.

That's right Mike. I have used a brand new 120 hp ej-20, and it had about the same get up and go as an ej-22 that had done a biy of work. This was on the same machine.

The latest ej-20 is supposedly 134 hp. I don't know about the weight as I don't seem to have the appropriate scales availible when I have the engines availible!!!:o

Could you check that ECU for me Mike. Is it the "Link" brand?

Aussie Paul. :)

[MikeBoyette]

Paul,
I think it is. I will check with dad. I know he liked it so much he ordered one for the ej25 on LifINO.

[GyroRon]

Mike, is LIFINO flying yet? Will I get a ride at New Years in it?

[LARRYEBOYER]

Chris!!! Looking good. If you need anything? call.
I would like to see the test start up!

[ben]

chris
if ya get a 120hp out of your ea81 which i think you can, if that wont do the job then a ej2.2 wouldnt either 130 hp and a 75 to 100lbs heavier.

[GyroRon]

Ben the EJ-22 might only be a few more horses, but it is a larger displacement engine and that means more Torque. More Torque equals more thrust!!! Plus a easy mod to the Subaru EJ is the Delta cam grind and that should bump power up close to 160 hp without too much stress on the engine.

[MikeBoyette]

Ron,
Not yet Dick took the gear box back up north to tweak. As far I know Dick and Dad will be test flying between New Years and BD's. Maybe a t Bd's but it will cost ya!!!LOL. "Nuttin free for Ronnie boy" that's Dad's motto.

[PW_Plack]

Ron,

More Torque equals more thrust!!!

Not a valid assumption if you're using redrives. Any two engines which can turn the same prop with the same pitch at the same RPM, will make the same thrust, because they're making the same HP.

If the bigger displacement engine has more torque but less HP, the smaller engine can make more thrust if both have optimum redrive ratios. The small engine with less crankshaft torque will be making more torque measured at the prop.

[GyroRon]

Paul, how many different ratio redrives have you seen for gyroplanes powered by Subarus? Nearly all are 2 to 1. Chris already told me he would reuse his Suza gearbox on the EJ-22 if he ends up going that way. So he would end up with the same ratio. Same ratio and larger displacement engine turning the same RPMS will likely result in more torque and a more thrust. Am I wrong?

[Butch S.]

The [failures] have been caused by detonation caused by poor fuel & poor spark control the STD sub distributors are not suitable unless you regraph them as to allow 20 deg at idol & 35deg max, total advance 15deg.
STD distributors allow 30deg + vac this is fine for old super but wont cut it with the **** we are being served up .so do the mods on your dizzy &
Don't worry be happy with your ea81 built right they do 2500hrs mustering
I do however like ej22sohc but they are 25-35kg's heavier
Butch

[ben]

ron
if i were chris and the ea81 doesn't work out, i'd bypass the ej22 and go for the sohc 2.5 for 165 hp.

35 more hp and almost the same weight as the 2.2 or maybe give the 2.0 tubro a look at 240hp talk about flying lol lol lol lol

[CLS447]

Matthew here is one of the threads I started.

[LARRYEBOYER]

Chris, Have you ran the engine with the new heads yet?

[CLS447]

Not yet Larry but soon ! I wanna come check out your new project...a 912 ,huh ?

I hope you didn't have to boot the wife's car out of the garage !

[LARRYEBOYER]

No, but the aircraft fusalage take up the bay where the Boyer Warrior was borne.i had a great weekend in the aviation realm. I worked on and flew the BW. logged 2 hours on the sweety pie.(my gyro for you dirty minded folks)
Installed the 912 in the Kitfox and installed the seat. I am hoping to finish the instriment panel this weekend and install.

Haven't seen you, Chris, in a coon's age. Bring Anthony over and let his mouth water. Thought you said he wanted to build a stol aircraft?

[CLS447]

We started the EA81 with the dual port heads.

With the same 12 degrees of pitch on the Warp it spins an extra 350 rpms.

Need to get a thermostat on to get the temps to 180.

Still running the old exhaust. I think this is gonna do it! Gotta talk to Ron at RAM about building the header & get a muffler on it.

Now that she has been run we need to retorque head bolts & readjust valve clearance. Then we will repitch prop to bring rpm's back to 5000 max. I hope to be needing 2 more degrees for this.

Need to tune carb with proper jetting. Considering replacing the 32/36 Weber with 38 syncronis Weber..... kinda costly....$380 If all goes well maybe Fuel injection ?

Hopefully just larger jetting will do.

Any ideas on how to get max performance from my existing carb ? Should I moniter EGT's or just check plug color ? What temps should I be after?

[automan1223]

Critical if you want the exhaust valves and other parts to hold up. You NEED to monitor all 4 cylinders. \

I like 4 probes, selectable 4 position rotary switch and a single sigtronics digital readout.

or whatever floats your boat.


One way or the other. More flow means more fuel.

on my 2.2 I try to keep it under 1450 f. average 1340-1425. f.



Jonathan

[CLS447]

Jonathan , how do you regulate your EGT's with the Holley carb ?

[automan1223]

Primarly, with the throttle ! :p

seriously you can jet a holley just like any other carb.
may require additional parts to make it the way you need it but now they are coming with all the bells and whistles right out of the box for the most part. along with the large price tag....

Jonathan

[CLS447]

OK... heads have been retorqued & valves readjusted. Also brazed copper extensions on the valve covers for my breather filters.

Auto Zone got my Weber book for me yesterday so now I can learn more about rejetting it.

Ron from Ram likes the Edelbrock EGO for tuning. It uses an O2 senser with LED's to show rich or lean conditions. Don't know if I want it permanantly installed or just use it for tuning & then just use an EGT for flying.

I just got my $150 in line thermostat housing from Wilson Manifolds that will need modification to accept 2 3/4" return hoses. Then Ron tells me they are using one from a BMW that works without mod ! $25 from auto parts store !!!!!

I think I am going to return the expensive one as soon as I get a look at the Beamer one. I just don't know the year & vehicle yet.

Does anyone know ?

Ron wants to make my SS header for me..... I hope it doesn't take long.

As soon as the coolant hoses are done, then the rejetted carb goes back on & the new throttle & choke cable can be routed.

New exhaust with Supertrapp muffler goes on......run her up again, hopefully realizing the engines full potential, repitch prop, take her back to airport & see what she's got.

Sounds so simple , doesn't it ?

I have also installed a set of Bosch platinum plugs, that should really make her go ! (or my money back)

[StanFoster]

Chris: I can just see your smile when you fire it up. I bet that motor will crank for you big time. Good luck...and I will be enjoying your flying pictures.


Stan

[Vance]

Welcome to the world of hot rodding. Your attitude, as always, is great.

Thank you, Vance

[GyroRon]

I thought we used Subaru engines on our gyros cause they were cheaper than purpose built aviation engines..... How much dough you got into that 4 banger by now Chris??? I hope it works out for you, I am sure it will fly you and Shar, just not sure how much spunk it will have

[CLS447]

Ron, I lost track somewhere!

If it don't work we'll sell the engine or use it on something else & go to an EJ25 with cams & fuel injection.

What engine would you recommend for my machine ?

[GyroRon]

Chris, I don't know.... I think with the weight and drag that puppy has, the old saying "there is no replacement for displacement" might be good for you! ;) That 2.5 would make that machine a real hoss and would also allow you to fly it at low throttle settings when just cruising around. The EA-81 I think will always be running hard to fly it period... But like I said I think with all the mods you have done it should fly you two, just not like a 2.5 Soob would. Heck it flew you two at ROC two years ago with the stock heads and so on, so you know with all the mods it should do better, at least that is way guess.

I do wonder if you could sell it to someone wanting a real hotrod subaru for a single place and get enough money to put a EJ25 with maybe a Sparrowhawk redrive on it?

[CLS447]

I think I would use the Autoflight gearbox

[automan1223]

Chris platinum plugs have a low melting point.

Spend the bucks and get a set of ngk IRIDIUM. HAS THE HIGHEST MELTING point for the electrode.

Have not let me down yet.

If not use copper.

Jonathan

[Aussie_Paul]

I think I would use the Autoflight gearbox

Definately the way to go.

Aussie Paul.:)

[LARRYEBOYER]

Chris! Good luck on your engine. You have put the effort forward, no doubt. Hope to see you and Shar realizing your dream. I know one thing. Regardless of how fast it climbs out, you will still look good in that dream machine!!!

[Brent_Brown]

What is the real flying weight of the EJ20 and what one do I want to get. All I find are turbos?

[Aussie_Paul]

What is the real flying weight of the EJ20 and what one do I want to get. All I find are turbos?

An ej-20 120 hp SOHC with an Autoflite redrive, ready to run, BUT no exhaust or radiator weighs 120kg/264 lbs.

Aussie Paul.:)

[Brent_Brown]

Ok Paul I sent you an email you can reply here if you want. Is there another EJ20 non-turbo that is used to get more HP? I would guess it is fatter too

[Aussie_Paul]

Ok Paul I sent you an email you can reply here if you want. Is there another EJ20 non-turbo that is used to get more HP? I would guess it is fatter too

Brent, the latest ej-20 SOHC non turbo engines we are getting are 134 hp. The 2.5 ltr version is 167 hp.

I have to get them through NZ.

Aussie Paul.:)

[Brent_Brown]

Did the weight go up with HP in the latest 2.0?

[Canadian Rhino]

I just got my $150 in line thermostat housing from Wilson Manifolds that will need modification to accept 2 3/4" return hoses. Then Ron tells me they are using one from a BMW that works without mod ! $25 from auto parts store !!!!!

I think I am going to return the expensive one as soon as I get a look at the Beamer one. I just don't know the year & vehicle yet.

Does anyone know ?


Just bolt any two regular thermostat housings together to make an inline housing!;)

[Aussie_Paul]

Did the weight go up with HP in the latest 2.0?

I don't believe so Brent. They have used lighter manifolds and it is possibly a small valve timing change to get the added hp.

The ej-25s have variable valve timing so we are looking at how to use that simply and efficiently.

Aussie Paul.:)

[CLS447]

The money pit !