Update #4 - GR86 / BRZ High-Capacity Oil Pan: Header Fitment, Early Testing, and Manufacturing Update

Development of the Formula Delta high-capacity oil pan for the second-generation Subaru BRZ and Toyota GR86 is continuing through pre-production testing, header compatibility checks, and manufacturing review. Recent work has focused on confirming fitment with additional aftermarket headers, collecting early track data, and preparing the design for production.

Several new header fitment results are now available. The Tomei equal-length header and JDL unequal-length header with catalyst do not fit the current oil pan design. The Tomei unequal-length V1 header is extremely close, with approximately 1 mm or less of clearance, so we cannot confirm compatibility due to normal manufacturing and installation tolerances. The Tomei unequal-length V2 header has been installed successfully by an early access tester, although final clearance confirmation was still pending at the time of this update.

The JDL equal-length header without catalyst is also a close fit. Based on the scan data, small shape changes to the production oil pan should allow this header to clear. These updates will be incorporated into the compatibility list as testing and visual confirmation are completed.

The pre-production pan is shaped closely around the OEM header heat shield, allowing it to fit without cutting or modifying the factory shielding. This is one of the main design requirements of the product. The current version provides approximately +1.3 L of additional capacity, with the production target increasing slightly to approximately +1.4 L through minor geometry revisions.

Provisions have also been added for turbocharger, supercharger, or auxiliary oil return plumbing. Reinforced areas on the upper portion of the pan provide enough material for a return fitting to be drilled and tapped or welded into place. Two potential return locations are available to support different forced-induction and catch-can configurations.

Early access testing is now producing usable track data. One tester submitted data from Streets of Willow using a lightly modified 2024 Toyota GR86 Trueno Edition with track alignment, wheels, tires, and brake upgrades. Additional data was collected from a more heavily prepared 2022 Toyota GR86 at Circuit of the Americas and another California circuit. Other pre-production pans are currently installed, awaiting track events, or moving through the installation process.

The early results have been positive and are being used to guide final production changes. The early access program is intended to confirm oil pressure performance while exposing the pan to different vehicle setups, track layouts, driving styles, tires, and installation conditions before the casting design is finalized.

On the manufacturing side, we are evaluating alternative vendors due to changing economic conditions, supply-chain uncertainty, and the risk of unexpected import costs. Selecting a new manufacturer will require new molds and machining tooling, but it also provides an opportunity to make minor design improvements before production. The goal remains to achieve the required balance of performance, quality, and cost.

Preorders will open once the manufacturing vendor is finalized. Early preorder customers are expected to receive discounted pricing, with those funds helping support the upfront tooling and production costs. Final pricing had not yet been confirmed at the time of this update, but the target remains well below $1,000 without unexpected tariff costs added afterward.

The production oil pan will continue to use RTV rather than a reusable gasket. The sealing surface on the FA24 upper oil pan is narrow, the mounting bolts sit close to the sealing edge, and the area is exposed to significant exhaust heat. Under these constraints, retaining the OEM-style RTV sealing method provides the most practical solution.

An FA20 oil pan for the first-generation BRZ, FR-S, and Toyota 86 is also under consideration. Development remains focused on bringing the FA24 version to market first, after which an FA20 application can be evaluated as a follow-up product.