Small update
Ended up with a fully disassembled ej253. Its currently at the machine shop being inspected.
I am having second thoughts about doing a build at the moment. I am worried the stock pistons will be too small for the honed block, I should've taken some measurements before sending the motor off but I didnt know what I know now. I also came across an 84mm crankshaft and decided I have to have more stroke. I am not going with the 84mm Cosworth crank seeing as it has a price tag of $4k, so the best I can do is an 83mm from Manley which is still pricey around 1500. I feel it is worth putting the build on hold for if I plan to keep this N/A, which today I do. So, I am going to actually look into what all my motor sounds may be. If they originate from the heads, I'll just swap them out so I can save the build for when I get the crank.
That said, what are your opinions on increasing stroke? Any downfalls? I am shooting for power low in the rpm range say 2k-4k.
Also, I know 100mm is the factory limit on bore but with proper ptw clearance and ring gap, would it be all that unreliable to go over that(in a non-turbo application)? IIRC I read of a larger displacement kit that calls for 103.XX mm bores. Didn't see anything about sleeves. I would probably go to 102mm max.
With increased bore and stroke I also plan on high comp pistons, delta cams most likely 1000 grind unless they want to try a custom low-mid range cut. Also machining the combustion chambers to match the bore/pistons, 3+ angle valve grind, light porting of intake and exhaust ports and port-matching everything. One minor drawback will be that I am not giving up the UEL header. I don't think I will care about the 10hp or so I will be missing out on.
From what I have read, I believe the final result will put as much power to the ground with 29" mud tires as a stock wrx. But this isn't gonna be built to race, it's gonna be a capable trail rig/dd/head turner.
One last thought, how much of an expected power difference would there be in a motor with a 79strokex99.5bore and 12:1 comp ratio and an 83x100 12:1?
Enough from me for now. Just waiting to hear from the machine shop at this point.