ej20 shortened oil pan

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Woodyyellow
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ej20 shortened oil pan

Post by Woodyyellow »

Thought I’d add this here as well as my ongoing restoration thread to enable the ‘search’ facility.

http://forum.club8090.co.uk/viewtopic.php?f=50&t=128706" onclick="window.open(this.href);return false;

As I’m going to install an ej20 into my van, one of the jobs to do was to shorten the oil pan.

Searching the internet, the best information I could find came from “The Samba”

https://www.thesamba.com/vw/forum/viewt ... p?t=685557" onclick="window.open(this.href);return false;

I mainly followed this technique and found it worked well.

I’m going to remove 1.5 inches which seems to be the standard amount to do and weld a 4mm thick steel sheet across.

Simple pencil gauge to draw a line at the correct height.

ImageIMG_1594 by Grandpawoody, on Flickr

Then confirm with masking tape.

ImageIMG_1597 by Grandpawoody, on Flickr

Looks a bit wonky but thats just the camera angle. Next stage to cut off with angle grinder.
Looks like a previous owner of the Impreza managed to ding the sump!
ImageIMG_1598 by Grandpawoody, on Flickr

I clamped the pan to a board so I could hold it securely in the vice, then cut round with an angle grinder
ImageIMG_1599 by Grandpawoody, on Flickr

The cut was quite easy to do
ImageIMG_1600 by Grandpawoody, on Flickr

ImageIMG_1602 by Grandpawoody, on Flickr

Then I checked for a good flat surface, needed a little tidying up but not too bad.

ImageIMG_1603 by Grandpawoody, on Flickr

ImageIMG_1605 by Grandpawoody, on Flickr

Simple ‘bucket chemistry’ gives a loss of 500 ml, so not too bad at all.

ImageIMG_1606 by Grandpawoody, on Flickr

This shows the temporary base board I used. Two main holes for oil pickup pipe and return oil pipe.

ImageIMG_1609 by Grandpawoody, on Flickr

Prior to welding the base, I did a final check that the oil pick up pipe was the correct length, and didn’t reach the bottom. I have about 6mm of clearance, the same as original.

ImageIMG_1612 by Grandpawoody, on Flickr

By screwing the oil pan down to this board I was able to easily hold it in the vice whilst welding the base, also I think it helped prevent the pan from warping from the welding heat.

ImageIMG_1617 by Grandpawoody, on Flickr

I welded the seam in stages, spacing the welds apart to prevent overheating in one area to eliminate stresses and warping.

ImageIMG_1620 by Grandpawoody, on Flickr

The oil drain thread was removed from the cut off oil pan and welded back into a suitable area.

ImageIMG_1613 by Grandpawoody, on Flickr

ImageIMG_1619 by Grandpawoody, on Flickr

The final test was to fill it with white spirits to check for pin holes, yes I found 2 but easy to re weld. Rather find them now rather that after installation!

The oil pickup pipe was shortened by 40mm. The tube was 20 OD so I was able to sleeve it with a short length of 22mm copper water pipe - 20mm internal - then silver soldered it into place.

ImageIMG_1610 by Grandpawoody, on Flickr

Again by using he base board I was able to align the filter head parallel to it whist soldering it.

ImageIMG_1614 by Grandpawoody, on Flickr

The finished oil pickup, painted with engine enamel.

ImageIMG_1621 by Grandpawoody, on Flickr

All done, very pleased with finished pan.

ImageIMG_1626 by Grandpawoody, on Flickr
Last edited by Woodyyellow on 04 Jun 2018, 18:21, edited 1 time in total.
1987 1.9 WBX DG Hi-Top. Soon to be Subaru ej20

I'm an old guy but I still learn new stuff!

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syncroandy
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Re: ej20 shortened oil pan

Post by syncroandy »

What an awesome post !

Surely one that deserves to be preserved in the Wiki ??
Syncrosport
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slowcoach
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Re: ej20 shortened oil pan

Post by slowcoach »

Great job! ! I chickened and bought an ally one, my stick welder not exactly suitable. Nice project :-)
===================
1984 TRAKKA Conversion Subaru EJ20 5 Speed

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Aidan
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Re: ej20 shortened oil pan

Post by Aidan »

bang tidy, thanks for posting
:ok

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irishkeet
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Re: ej20 shortened oil pan

Post by irishkeet »

excellent job :mrgreen:
------------------------
1985 Doka 1.9 DG 4 Speed Box
---
1986 Fakefalia Syncro Subaru EJ25

matt brighton
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Re: ej20 shortened oil pan

Post by matt brighton »

slowcoach wrote:Great job! ! I chickened and bought an ally one, my stick welder not exactly suitable. Nice project :-)


Hi

Can you let me know how much and where from for the ally oil pan please ?

Thanks


Matt

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slowcoach
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Re: ej20 shortened oil pan

Post by slowcoach »

matt brighton wrote:
slowcoach wrote:Great job! ! I chickened and bought an ally one, my stick welder not exactly suitable. Nice project :-)


Hi

Can you let me know how much and where from for the ally oil pan please ?

Thanks


Matt

thers more details on this thread - http://forum.club8090.co.uk/viewtopic.p ... 9&start=15" onclick="window.open(this.href);return false;

i was also talking to someone called Nick Tune on facebook - hes on a t25 group, and manufactures steel ones. they look good, though dealings with him were err, odd. and as soon as i asked about any kind of returns warranty if it turned out to leak or didnt fit right, he aborted all commuinication and told me to get one somewhere else. so forget that - not someone id want to deal with!!
===================
1984 TRAKKA Conversion Subaru EJ20 5 Speed

matt brighton
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Re: ej20 shortened oil pan

Post by matt brighton »

Well its a fair question and not an unreasonable request

Probably best to avoid then - I don't go off roading like the syncro lads ... "its gripped - sorted !" fast show late 1990s :ok

Tesco car park speed humps are about as off road 4x4 territory as i go and a few scooby converters have said they didn't bother with the short pan and its a higher clerance than was on my old alfa 159.

I have big fat tyres too which raises me up a few inches so I'm not bothered for now anyway about the same clearance.

Thanks for the reply to my post


Matt

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