newbie tj owner attempting a 4.6

[krisk416]

Let me start off with I have an 01 TJ with 177k miles. It has started a slight leak on the head gasket and every month i need to add half a qt. There is no problem with the oil/coolant yet but its probably a matter of time. I decided to stroke it since i need to do a rebuild which is why i am here. however besides the basics the most i have done is the valve cover gasket (to make sure it wasnt the leak) and that is it. It is my daily driver so i cannot take it out of commission for long (i can barrow a family car) and do not have the money to spend on another engine to build on the side. I live in florida so my wheeling is not extreme and it will definitely see mud before 90° .. Ive read this stuff but i think at this point i am just confusing my self and could use some help. I am aiming for the 4.6 poorvmans stroker. It seems as those there is a lot of older jeep projects on here and am not sure how it applies to my block.

4.6L Modified "poor man's" stroker

Jeep 4.2L 3.895" stroke crank
Jeep 4.0L 6.125" rods
Custom forged +0.020" bore pistons, compression height 1.380", dish volume 26cc
9.25:1 CR
Stock 4.0 camshaft
DIY ported HO 1.91"/1.50" 57cc cylinder head
Mopar/Victor 0.043" head gasket
0.043" quench height
Ford 24lb/hr injectors for '87-'95 engines, Accel 24lb/hr injectors for '96-'04 engines, '98 Chevy LS1 25.2lb/hr injectors for '05-'06 engines

1. Do i pull the engine then order the parts or do i order the parts and tell them how i wish to have the block milled?

2. I dont know how to approach this: "Custom forged +0.020" bore pistons, compression height 1.380", dish volume 26cc"

3. Which brand stroke crank do you recommend. Also i have read some people needing to cut or add a spacer (would this apply to me?

4. Has anyone used NAPA for their cylinder head porting/milling?

Lastly: ive read 62mm throttle body that i dont see listed here and 2.5in exhaust which i believe i have (not sure as it came with an exhaut already) and a new high pressure oil pump, i would probably replace the current one since it is apart but do i need it to be high pressure.. That goes for water pump as well?

** i would like to continue running 87 octane if possible

Sorry for the long thread i know there is a bunch of questions, thank you for your time

[Cheromaniac]

The only aftermarket parts you'd need to order for the stroker build are the 258 crank, custom pistons, and oversize injectors. Contact Russ Pottenger about those as I'm sure he'll help you out. Your connecting rods will need to be checked and may need to be resized depending on condition. A new set of ARP 112-6001 rod bolts will be required if you reuse your existing rods. Rod/main bearing undersizes will depend on whether the journals on the 258 crank have been reground.
Any 258 crank from '72+ would do, but the cranks from '87-'90 have the same snout length as the 4.0 crank and don't require a 10mm thick spacer to be placed in front of the harmonic balancer to maintain the correct position.
All other parts you'll need (water pump, oil pump, timing set, freeze plugs, upper/lower gasket sets, cam bearings, pushrods, lifters) would be the same as for a stock rebuild. A stock oil pump and water pump would do fine.
A 62mm throttle body and a 2.5" exhaust will help your stroker breathe and make the power it should.

[krisk416]

Ok thank you! I sent him a message i hope to hear back soon.