Update #2 - GR86 / BRZ High-Capacity Oil Pan: Fitment, Early Access, and Manufacturing Update

Development of the high-capacity oil pan for the FA24 Toyota GR86 and Subaru BRZ is continuing through header fitment validation, early access planning, and manufacturing quality control. The latest work has added several compatibility results while also identifying areas that need refinement before pre-production pans are released for testing.

The HKS turbo header has been confirmed to clear the oil pan, and the pan includes provisions for a turbo oil return. A first-generation Tomei unequal-length header with 42.7 mm tubing was also scanned, but clearance was approximately 1 mm. Because of normal manufacturing and installation tolerances, we cannot guarantee fitment for that header without minor modification to the pan or header.

We are continuing to expand the compatibility list and are specifically looking for scans of additional JDL headers with catalyst. Customers in the Greater Toronto Area with unverified headers may be able to arrange an in-person scan. For remote fitment checks, a usable 3D scan is strongly preferred. Photographs can provide context, but they are not accurate enough to confirm clearance with confidence.

The early access program remains open to a limited number of suitable testers. Priority is being given to vehicles with oil pressure logging capability and confirmed track use during the winter and early spring testing period. Testers will be expected to provide data and installation feedback, and discounted pricing will be available for accepted participants.

The first batch of pre-production samples has also completed an initial design verification review. Material quality, casting consistency, machining, and dimensional accuracy were evaluated, and several areas did not meet the required standard. We are working with the manufacturer on process improvements and minor design changes before approving additional samples. This will delay the early access schedule, but pans will not be released for testing until they pass the required quality checks.

The existing samples are also being used for secondary validation, including pressure testing, destructive inspection for casting porosity, and measurement of machined features. These checks are intended to identify manufacturing risks before the production run begins and reduce the likelihood of fitment or durability issues later.

The production pan will include integrated baffling and metal trap doors. Additional aftermarket baffles are not recommended because the internal system is intended to provide the required oil control as a complete assembly. The move from rubber flaps to metal hinged trap doors also removes the periodic replacement concern associated with some rubber trap-door designs.

Provisions for turbocharger, supercharger, and other oil drain-back requirements are incorporated into the pan. Reinforced locations will allow suitable fittings or bungs to be added in areas that are practical for common forced-induction layouts.

Pricing is still expected to remain below $1,000, with final pricing dependent on the manufacturing arrangement and production quantity. The current target is an early spring release, subject to successful completion of the pre-production quality and track-testing phases.