Hi everyone, I’m looking for some advice on head gasket sizing for my Subaru EJ207 build.
My engine is being rebuilt with a TOMEI EJ22 stroker kit, which uses a 92.5mm bore.
The current head gasket is a Cometic C4261-040, with a 93mm gasket bore and a thickness of 0.040” (approximately 1.016mm).
However, according to TOMEI’s EJ22 stroker kit specifications, the recommended gasket bore is 93.5mm.
Here’s my concern:
Cylinder bore: 92.5mm
Current gasket bore: 93mm
Bore diameter difference: 0.5mm
Radial clearance on each side, assuming everything is perfectly centered: 0.25mm
With a 93.5mm gasket, the diameter difference would be 1.0mm, giving 0.5mm of radial clearance on each side.
I’m concerned that the 93mm gasket may leave too little clearance around the cylinder bore, especially under high boost, high temperatures, and sustained high-RPM operation.
I understand that the gasket is clamped between the cylinder head and block, and that gasket bore size alone doesn’t determine sealing reliability. However, I want to make sure the gasket’s inner edge and sealing structure are appropriate for this particular setup.
My questions are:
Has anyone run a 93mm head gasket on a 92.5mm bore EJ20/EJ207 without issues over the long term?
Is a 0.25mm radial clearance generally acceptable for this type of engine, or is a 93.5mm gasket the safer choice?
Has anyone experienced head gasket failure, bore-edge damage, or sealing problems caused by an undersized gasket bore?
Would a Cometic 93.5mm gasket or a suitable TOMEI 93.5mm gasket be a better choice for this build?
I’ve had a head gasket leak on a previous engine, so I’m trying to be particularly careful with this rebuild. The engine has not been assembled yet, so I still have the opportunity to change the gasket if necessary.
I’m not trying to second-guess my engine builder without reason. I’d just like to understand the engineering considerations and hear from people with direct experience running similar setups.
Any advice or firsthand experience would be greatly appreciated. Thanks!