RRich:
I would say that my good handle on the subject is more like a minor clue. What goes on behind the torque convertor is all very mysterious magic. Probably Wizards and Fairies back there, for all I know.
I'll try to answer your questions the best I can. Unfortunately English is the only language I can communicate in fluently, but do a weak job at getting my point across some of the time. Here goes:
A smaller convertor, (diameter), would generally have the same pitch as the larger convertor. Since there's less mass to move, it would have a higher stall, remembering that on the back turbin blade, it too is smaller, but has to move the same internals in the tranny to get the car to move. Of course, there's a myriad of variables on how that smaller convertor could be made. It could have even less pitch/bite/flatter or it could have more. Theoretically, you could increase the pitch enough to compensate for the smaller diameter, but at some point, there would be too much stress on the blades, unless you went to exotic metals. Also, regardless of pitch, you still have a smaller diameter container, so to speak, which holds less fluid, which will cause the tranny to run hotter. The smaller the convertor, the larger the cooler you need to compensate. In my case on my '76 Waggie, I tried a 10" convertor that was advertised to increase torque. It was really designed for a souped up motor that doesn't develope any power until above 2500 rpm, right where the majority of us tend to peak out. I talked the manufacturer, (TCI), into exchanging it for their RV convertor, which was 12" or 13", can't remember. Much better. When you stepped on the gas from a stop, you moved. The 10" was like a clutch that was worn out slipping waaaaaaaay too much before you'd start to move.
You can get anything from A-Z in a given size of convertor. Kinda like the variables for cams. Two convertors of different diameter with the same stall speed could have different results in power delivery. I think they are rated statically and not for the application of your particular use, which could vary depending on the engine and the weight of the vehicle.
Yes, a smaller diameter, generally, for a smaller engine. But, in the case of the stock Jeepster, I would personally rather investigate in a stock, (12" or 13", which is it, anyone?), with less pitch, going back to that greater fluid capacity thing, running cooler. This would be rated in stall speed. I believe the stock convertor's stall speed is in the 1200-1600 rpm range. This works great for a 350. My guess would be a 1600-1800 stall speed would be less bog for 225/231/252 V-6's. I switched to a 700R4 in my Jeepster, which is the equivallent to a TH-350 w/o.d. It has a smaller convertor, but can't remember what diameter. I do remember the drag on the 225 and 252 motors when I still had the TH-400 in it.
As far as lockup goes, my understanding is there is always some slippage in the older non-lockup convertors used in TH-350's, 400's and other brands. This is why highway mileage is always better with a manual tranny. The newer trannys w/lockup narrows the gap, but still there's slippage until you get thru all four gears and it locks up.
The greater power from a juicebox comes at lower rpms where the slippage causes that torque multiplication thing that I don't entirely understand. This is why on new vehicle purchase, you always get the automatic with the HD towing package, I believe. The juicebox will pull more weight than the standard manual.
As far as the crawler project goes, I'd opt for a lower stall convertor, (stock, but H.D.). You've probably seen the competition rock crawler buggies out in the desert, I'd think. I know that the trend is to go juicebox over manual these days, probably because of that torque multiplication thing and one less pedal to operate. Are they winding their engines up a lot before they start to crawl? If not, then they are using stock stall convertors, most likely.
Quad 4. Isn't that a Kawasaki or something?
I've been a southerner all my life. Lived in southern CA, southern NV and now southern WA. Can you detect my southern accent?
Let us know if you run into Art Carr and what you learn. I'm sure he's got more knowledge on juiceboxes in the tip of his pinky than I have in my whole empty head.
Tim
'66 Jeepster Commando w/Buick 252/4.1L V-6
'70 Wagoneer w/Buick 350 V-8
'76 Wagoneer w/AMC 401 V-8 (sold)