Project 4.5 Build Plan - - Jeep at Off-Road.com
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Project 4.5 Build Plan

Source: Jeep at Off-Road.com

I will say up front that this plan is still somewhat under construction. There are finer points that need to be worked out, but for the most part the information here is a good basis for starting the build. Additionally, the block setup is a fairly standard 4.7 stroker offered by HESCO. I would not even think of trying to make this combination of parts sound like something I came up with alone. As you can see in Terry's build plan, we are working from fairly basic parts list, with some basic building changes to make them either more efficient or more powerful.

The 258 was not a big hp motor, but it produces great torque. If you sit a 242 crank next to a 258 crank you will see why. The 258 crank is beefier, and heavier. The rod and main journals are the same size from my measurements, but the 258 has more counter weights lugs, 12 to the 242's 6. This becomes the main building block for our block. Add to this forged 242 pistons and magnifluxed rods, in cylinders bored .60 over and you have just increased your 4.0L to roughly 4.7L. Oddly enough the 242 rods are heavier and when magnifluxed should produce cleaner hp and longer life.

Interestingly enough Bennie said a stock head with heavier valve springs and roller rockers, in his opinion, was a great combo. I will say that the only thing I might add to this is a three angle valve grind and good quality parts. The three angle valve grind is a basic performance trick. Although some would argue that for daily driving that this step will only produce for the first 5000 miles or so. I will see what the cost trade off is for this and let you know.

Aside from these basic changes, I plan to add a Borla, or similar, header, a blueprinted Clifford factory oil pump, and if needed 10% over fuel injectors and/or a HESCO oversized throttle body. This combination should produce a conservative 200 - 220 hp. I don't have a dyno, but I am looking into Mr. Gasket's Desktop Dyno. This will allow me to input the stock engine specifications and make these changes on my PC. It should give me a slightly closer idea on actual possible horsepower.

 

Internal Upgrades
Cylinders.60 over bore
Pistons242 HESCO Forged
Rods242 HESCO Magnifluxed
Crank258 stock
Cam242 stock (or stock '96 TJ)
HeadRoller Rockers Heavy Springs Quality Valves 3 Angle Valve Grind
Push RodsStock Chromoly
LiftersStock
Oil PumpClifford Factory Blueprinted

 

External Upgrades
IntakeStock
TbodyStock (or possibly HESCO oversized)
Fuel InjectorsStock (or possibly HESCO 10% over)
ExhaustBorla
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