I think you defiantly want to use a 2 stage pump the principle is that it runs in the higher GPM lower pressure stage to perform the unloaded action which would be most of the ram travel. It switches over to low GPM high pressure when the load demands such as when the block is actually being spilt, quite often this is only somewhere between 3 and 10 inches worth of travel unless there is a stringy stubborn block in. even then many times it will go back to high GPM once the “back” of the block has been broken so to speak. Otherwise the single type of pump options would end up to be either a higher GPM lower pressure pump which would require a non practical amount of HP, or the low GPM high pressure pump which would make for ungodly slow cycle times.
If mobility is not an issue, then an electric motor could be a good choice since it is much more efficient, Northern Tool used to have a conversion chart in their paper catalogs a long time ago that compared electric, gas, and hydraulic motors I think a 1 hp electric matched up to about a 2 1/2 hp gas. It would be basically about torque and duty cycle. If you decide on electric, I would choose a farm duty or commercial duty motor; if it is readily available to where the splitter will be use I would opt for 220 volts as opposed to 110. One advantage with electric will be maintenance, no worries about oil changes spark plugs or tune ups, another is the noise difference, and there also is no exhaust. I had a friend who used an electric motor, he had a large machine shed and hebrought the blocks inside with his FEL, he split inside with no concern for the elements. Since he piled his wood in there any way he felt it put him way ahead the game when he would take the split pieces right off the splitter and put them directly onto the pile. I had to admit it looked pretty good in winter when, at 20 below he would have a nice fire in the stove while he split in his shirt sleeves, while I on the other hand would be doing the same outside with 3 layers clothes, taking my jacket off as the work made me too warm and back on when I slowed down, all the while my hands freezing no matter what I did. Here is one site that may be of interest in comparing gas to electric.
http://www.baumhydraulics.com/files/infobuild/measure_torque.pdf
As far as the cylinder goes, whether you would really need a 5” instead of 4” depends on the wood you plan to split, the price difference stings a bit when you go to buy them. But I have never said “dog gone it I wish my splitter did not have so much power”, I have never seen the difference in cycle time be an issue in a hand feed splitter. With a valve that has a detent in the return stroke, that time is usually used up either getting next block into place or clearing the split pieces out the way; in my experience with a manually feed splitter in the long the man power portion can never outwork the machine. Now it is true that when I was 18 the splitter my dad had me using was me swinging a maul and I could out split any splitter for an hour or two, but splitting all day on a 20 cord pile the slower machine would still win out. In my old age I have grown to favor the 5” cylinders because I feel the pump and motor are the heart of the machine and the 5” cylinder makes the work easier on them which prolongs their life. I also believe that with pump J J listed and a 12 hp motor you would be hard pressed to ever find a block knotty or other wise tough enough that a 5” cylinder would not crack with ease, just make sure the I beam and wedge are sufficiently stout enough since it will generate in the 40 to 50 ton range of splitting force.
As far as plans go if you google using “wood splitter plans” there are over 38,000 results one decent one is at
Log Splitter Plans, Wood Splitter Plans, How-to, Ebooks
the price is reasonable ( $8.95 for 24” and $10.95 for 30”) and the finished products looks pretty good, with or without plans I would go look at as many commercially sold splitters as you can, get up close and personal and do your best to reverse engineer them. Building them is not rocket science and it is pretty easy to see the design and how they are built just by looking closely. There many different designs that have some great functions to them. IMO the best splitter you can make would be by looking at all the designs you can and taking the qualities that will best suite you and what you want from your splitter. I also believe that there is nothing with your home built splitter being a work in progress, remember if you make it you can change it just as easy. I often hear folks talk about the money they saved by DIY, but that is just a part of what is great about it. The best part I feel is that it gives you power to end up with EXACTLY what YOU want and need and not some one else’s concept of what that is. When you build your splitter and then figure out you saved maybe $500 to $1000 or so on what you could have bought one from the local dealer for, stop for a minute and consider how much the dealer might have charged if you had them custom build one to your specifications. Over the years I built several splitters and have helped friends build even more. I feel my best advice that I gave was to have the goal not so much to be how much money they could save but to end up being able to say “I love my splitter, it’s the best I have ever seen”
Have fun building