Novak Conversions Jeep Wrangler TJ radiator

A lesson learned—keep it light and nimble!

On my to-do list is the armor install, which will include Savvy corners and rockers. That said, I have two questions.

1. It seems logical to install the rockers first, then do the corner armor. Is this sequence correct?

2. I've ordered a new 17/32" drill bit for the nutserts and a Blair 3/8" Spot Weld (Rotabroach) kit (1st link below). The kit comes with a drill bit pilot. However, I noticed there's also a non-drill pilot (2nd link). Is there a preference for which pilot style to use?

https://www.amazon.com/dp/B002XML5HK/?tag=wranglerorg-20

https://www.amazon.com/gp/product/B0015S9ZG6/?tag=wranglerorg-20
Never used the skip proof but you don't need a pilot at all for pre-drilled holes in armor. Turn the cutter slow and it self centers which is what makes it a thing of beauty.

If that bit is the size I think it is based on spotwelds I've seen with small holes in the underlying piece after being cut, it won't take much to break them. Slightly off square when the cutter hits and you will need a lot of bits that size.
 
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I've used a spot weld cutter like the second one linked and it was the most difficult tool I've used. The bit kept walking and no matter what speed I tried it at I couldn't figure it out. The spring loaded punch in the center sucked. I didn't buy the tool (I was helping out a friend replace a front clip on a Civic hatch) so I cant say whether it was a quality tool or not.

After that experience my preference would be one with a pilot bit
You are supposed to use the center punch in the middle of the spot weld first. If the cutter skips out, then the tension on the spring loaded plunger is too low, center punch is too shallow or the cutter isn't hitting the surface square.
 
Never used the skip proof but you don't need a pilot at all for pre-drilled holes in armor. Turn the cutter slow and it self centers which is what makes it a thing of beauty.

If that bit is the size I think it is based on spotwelds I've seen with small holes in the underlying piece after being cut, it won't take much to break them. Slightly off square when the cutter hits and you will need a lot of bits that size.
I bought the center punch style also. I'll experiment a little first, before the real application!
 
Having recently used a Blair spot weld cutter to cut about 60 spotwelds, I'd say get the drill pilot. Even with the drill pilot, I had to concentrate on keeping the drill square, or the cutter would walk. Low speed, low pressure until the cutter is established, then low speed and heavy pressure. Oil the cut too. Went thru all the welds I cut with a single cutter. It's WAY better than the HF version.
I use high speed to start and then slow down. My helper uses low speed since he struggles to keep a drill square. I use high speed, light pressure and watch the cut line to square up the drill and then slow down when it is cutting a complete circle and has a ridge cut so the cutter will stay put.
 
You are supposed to use the center punch in the middle of the spot weld first. If the cutter skips out, then the tension on the spring loaded plunger is too low, center punch is too shallow or the cutter isn't hitting the surface square.
Good to know! After that night of drilling out almost 100 spot welds we both swore it off lol
 
Good to know! After that night of drilling out almost 100 spot welds we both swore it off lol
Too bad, there are few tools that work as well for drilling holes in sheet metal as that one. My favorite use is when I have to offset a hole that lands halfway on an existing hole. We have a piece of 1/4" strap that we drilled a 17/32 hole in. I center that over the new hole from drilling through the armor and clamp or screw it in place. The rotabroach will drill a perfect round hole without skipping, sliding or tearing up the sheetmetal.
 
Too bad, there are few tools that work as well for drilling holes in sheet metal as that one. My favorite use is when I have to offset a hole that lands halfway on an existing hole. We have a piece of 1/4" strap that we drilled a 17/32 hole in. I center that over the new hole from drilling through the armor and clamp or screw it in place. The rotabroach will drill a perfect round hole without skipping, sliding or tearing up the sheetmetal.
I may just have to go back on my word and give the tool another try. I'm sure it was just inexperience making it tough... and knowing my friend he probably bought a cheap bit.
 
I may just have to go back on my word and give the tool another try. I'm sure it was just inexperience making it tough... and knowing my friend he probably bought a cheap bit.
Sounded like you were using the Blair stuff. If not sure, give it a try, it is an outstanding way to drill round holes in sheet metal.
 
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I'd much rather sound stupid than make another simple mistake. Sometimes the obvious is!
My help spends a lot of time trying to line up the bit in the center of the countersink. I get it close, start it spinning and go in. He hasn't figured out that you could spend a very long time trying to drill off center on purpose and countersink will funnel it right to the center of the hole every single time. Also be aware that the hole in Savvy armor is slightly under 3/8" so the bit will cut the aluminum slightly.

Just make sure that the armor is clamped in place exactly where you want it. The rota broach will hit all the holes perfectly. When we remove to add nutserts and then put it back up, I use the exactness of the hole in the sheet metal to line up the holes in the armor to put it right back exactly where it was when it was drilled.

Some of the holes on the underside of the aluminum backer are too deep for the shoulder on the broach. We use a good 3/8" drill bit to locate them.
 
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I build my own rear links. All you need is:
https://www.amazon.com/gp/product/B01M9BXK5Y/?tag=wranglerorg-20

and any 1/2"-20 all thread, like:
https://www.amazon.com/dp/B00G3OM82A/?tag=wranglerorg-20

Once cut to length, I cover them with black wire loom.

For the front, I would either go with JKS disconnects, a Antirock, or Swayloc. This choice is based on your budget and needs.
Well here's an interesting problem with the JKS disconnects. Where I'm at now I don't want to spend the extra money on an Antirock or Swayloc, and I already had the JKS disconnects in mind. JKS has two different sets, one is for 0-2" of lift and the other is for 2.5-6" of lift. My bet is on the 0-2" set, but for people wanting to upgrade further down the road I'm wondering if the longer set could work for this application :unsure:

EDIT

I found some rod ends on McMaster that are PTFE Lined and a little bit cheaper than the ones from Amazon, I'm not sure if you've had issues with noise from the ones you've used but that seems like a possible concern that I'd like to address early.
 
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Do you notice and fuel mileage gains or anything like that? Or more of a general peace of mind and reduced wear thing?
As @Fouledplugs said, it's more of a cure for drive-line related vibrations. There is no gas mileage improvements and it actually introduces more complexity and maintenance, because you now have to clean and repack bearings routinely. I do mine on an annual basis, or ad-hoc, if needed.

On the flip side, the stock hub bearings are dirt simple and durable. However, this means that the front axle, along with all the attached parts, is constantly in motion. I've gotten so used to lockout hubs over the years that when the front driveshaft is spinning, at highway speed, it feels abnormal to me.
 
I found some rod ends on McMaster that are PTFE Lined and a little bit cheaper than the ones from Amazon, I'm not sure if you've had issues with noise from the ones you've used but that seems like a possible concern that I'd like to address early.
Share a link, so we can all look! ;)
 
Novak Conversions Jeep Wrangler TJ radiator