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  #1  
Old January 6th, 2019, 20:39
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Gratuitous Lack Of Moderation - A little stroker build

Well, since Project Unicorn blew the engine some time back, I've been considering what to do for a replacement.

I talked about it with Mr. Russ Pottenger, and he kindly took the blown engine from 4643 apart and found that a surprising amount of it would be reusable, and figured we could probably knock a stroker together without even getting into 4 digit dollars. I liked that idea, so we set out figuring the details and getting parts on ordered.

Somewhere something went terribly askew. I've forked the build thread off here so we can document the build of "GLOM - The strokerator". Because I refuse to own anything called the "unicorn stroker".
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Old January 6th, 2019, 20:46
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Re: Gratuitous Lack Of Moderation - A little stroker build

Cool, looking forward to the thread. I need to call Russ and talk to him about an engine or 2. Have one I need to reassemble into a stock class baja racer and the other for my badly knocking DD.
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Old January 6th, 2019, 20:57
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Re: Gratuitous Lack Of Moderation - A little stroker build

I'm going to go slow here and may cheat with my moderator powers to come back and correct the technical stuff here on this thread as Russ straitens me out, but we've decided to try and drop some details here.

Started off with a 99-04 NVH block.



Russ punched it out to .060 over and chopped the top off of the deck, and set me to washing it.

Started off with a large assortment of brushes.



Lots of scrubbing the outside.



Lots of scrubbing the inside.




And into every oil passage.







And a good hot water rinse.



I didn't take any pictures, but after this I wiped every machine surface down with Marvel Mystery Oil to prevent flash rust, and then painted it.



And then I got criticized for not painting the back red. I don't know why red, but it got done.

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Old January 6th, 2019, 21:03
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Re: Gratuitous Lack Of Moderation - A little stroker build

And then into the shop for some work.

Cam bearings.









Russ marks the bearings with an "up" line so the oil hole stays lined up.




Even though he carefully aligned them, he went back and checked to make sure the holes passed through correctly for every oil hole.

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Old January 6th, 2019, 21:16
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Re: Gratuitous Lack Of Moderation - A little stroker build

Next Russ started prepping the rods and pistons.


Russ has his own rods made. They are forged steel H beam chromoly and bushed for floating wrist pins.




The caps are doweled for additional strength.



Next to a stock rod you'll notice they are far more substantial, and you will also notice there are no balancing pads - so they clear the girdle in a late model block without grinding. I managed to not get a picture of it, but they also have ARP bolts.



So he installs the bearings, torques the bolts. He measures the corresponding rod journal on the crank, and zero's his dial bore indicator to that exact size, and then uses it to check the rod bearing clearance on a per rod basis.





This rod has roughly 2.5 thousands bearing clearance.



Number the rod (and cap) so you are sure to put it in the right place later, and then also label which side points forward.



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Last edited by cal; April 27th, 2019 at 06:48.
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Old January 6th, 2019, 21:27
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Re: Gratuitous Lack Of Moderation - A little stroker build

Russ also has his own pistons made. In fact I think a bunch of you are familiar with his pistons.

But you aren't familiar with *these* pistons.

Edelbrock a couple of years ago released a new aluminium head for the 4.0. They missed a lot of opportunities as far as upgrades goes, but the one thing they got right was reengineering the combustion chamber instead of re-using the same AMC chamber from 1941 (1941! jeep used it until 2006). The combustion chamber is a bit smaller both in CC (55) and overall footprint, giving you a better quench zone.

Russ had new custom pistons made to take advantage of that.



You'll notice unlike any other 4.0 piston (at least that I have seen) to date, these are not all the same. They are asymmetric to match the intake/exhaust orientation of their cylinder. They are forged high silica aluminum (4041? he told me and i don't remember the exact compound). He feels its the best compromise between strength and user friendliness. My particular pistons are a 3.935 bore, 1.385 compressed height and a 14cc dish.




Compare to his standard iron head pistons.



And to really show what we mean.




Back to building.

Once we establish which pistons belong to which holes, we need to label 'forward' so we don't put them on backward.



Toss the rod in the rod vice, slide the piston on, slide the pin in, drop in 2 C clips, and then re-mark 'forward'.




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Last edited by cal; January 6th, 2019 at 22:04.
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Old January 6th, 2019, 21:31
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Re: Gratuitous Lack Of Moderation - A little stroker build

Once the pistons are hung, its time to toss the crank bearings in, and torque the caps down.



Measure each main journal.



Zero out the bore indicator.







Measure the corresponding bearing.



And repeat the entire process over and over again, removing caps as we go.

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Old January 7th, 2019, 05:32
Redsnake Redsnake is offline
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Re: Gratuitous Lack Of Moderation - A little stroker build

GREAT thread so far!! Awesome to follow-along w/this one.
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Old January 7th, 2019, 06:10
XJwonders XJwonders is offline
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Re: Gratuitous Lack Of Moderation - A little stroker build

Yep. Great thread to follow.
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Old January 7th, 2019, 12:52
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Re: Gratuitous Lack Of Moderation - A little stroker build

sweet. What displacement?
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Old January 7th, 2019, 16:38
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Re: Gratuitous Lack Of Moderation - A little stroker build

Something interesting I see here. I know there is a good reason for doing it but I just so not know the reason.

There is a diagonal grove across the camshaft bearings, Why is that?

I have rebuilt dozens of engines as a marine mechanic,... Fords, Chryslers and mostly GM's and I never seen that.

It is good to see Russ is almost as meticulous as I used to be when rebuilding an automotive 350 block to change it from 260 +/- HP to 500 + hp to do amateur boat race.

Post up some dyno numbers. Reading this sends shivers down my spine with anticipation and excitement. Beautiful job!!
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1996 XJ; 4.0L; AW4; NP231; SYE; D30 and D44; ECTED; 4.10 gears; 30X9.5 -15 BFG/AT/KO; 3" lift; Rusty's LCA; JKS ADJ UCA; Kevins ADJ Track bar; Drawtite Front Receiver; Dual Electric Fans; Dual Battaries.
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Old January 7th, 2019, 18:33
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Re: Gratuitous Lack Of Moderation - A little stroker build

Quote:
Originally Posted by techno1154 View Post

It is good to see Russ is almost as meticulous as I used to be when rebuilding an automotive 350 block to change it from 260 +/- HP to 500 + hp to do amateur boat race.

You may not know this about Russ but 1500+ horsepower Chevy is his bread and butter. Strokers were a hobby that has become profit after the LS changed the hot rod scene.

As far as that bearing goes, it's just that one, and all 4.0's are apparently that way. Dunno why, but I asked about it too.
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Old January 8th, 2019, 06:16
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Re: Gratuitous Lack Of Moderation - A little stroker build

Quote:
Originally Posted by cal View Post
You may not know this about Russ but 1500+ horsepower Chevy is his bread and butter. Strokers were a hobby that has become profit after the LS changed the hot rod scene.

As far as that bearing goes, it's just that one, and all 4.0's are apparently that way. Dunno why, but I asked about it too.
That is what makes him a pro. I am just a novice who have a few dozen rebuilds mostly to original specs. Looking at a pro doing meticulous work remind me of my past.
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1996 XJ; 4.0L; AW4; NP231; SYE; D30 and D44; ECTED; 4.10 gears; 30X9.5 -15 BFG/AT/KO; 3" lift; Rusty's LCA; JKS ADJ UCA; Kevins ADJ Track bar; Drawtite Front Receiver; Dual Electric Fans; Dual Battaries.
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Old January 7th, 2019, 18:34
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Re: Gratuitous Lack Of Moderation - A little stroker build

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Originally Posted by denverd1 View Post
sweet. What displacement?

Loosley 4.7, 11.35:1 compression.


If you want exact numbers you need to wait until we're done measuring.
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Old January 8th, 2019, 08:48
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Re: Gratuitous Lack Of Moderation - A little stroker build

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Originally Posted by cal View Post
Loosley 4.7, 11.35:1 compression.


If you want exact numbers you need to wait until we're done measuring.
close enough for me. got a target HP in mind?
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