Novak Conversions Jeep Wrangler TJ radiator

2005 TJ Current Build & Future Plans

Logan97

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Original poster
Joined
Apr 23, 2021
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7
Location
Ruston, LA
Hey guys and gals! I've recently started the process of overhauling my '05 TJ and just wanted to start a thread to show where I'm at so far and then add to it as new parts come in and I get them installed. Feel free to add to this thread if you have any comments or questions about anything I've already done or plan on doing.

Currently, my Jeep is set up with a 3" suspension and 1 1/4" lift from Zone, aftermarket bumpers that I don't remember where they're from, and Banks ram-air intake and cat-back exhaust. My suspension was redone probably 5ish years ago with Rubicon Express control arms and trac bars while I was in college, and I've recently added a Currie front swaybar and Currectlync steering. Lastly, I also have Mickey Thompson tires (33") and wheels (15") along with Black Magic front rotors, calipers, and pads.

Last week, I placed an order for the Currie high pinion front Dana 44 axle with 5.38 gear ratio and Eaton E-locker. While I have the stock axle assembly removed, I plan to switch to a complete Currie suspension system which whill include 4" springs, adjustable control arms, trac bars, and possibly the rear antirock swaybar. I know the rear swaybar isn't really necessary, but we'll see how I feel when I make my way to the rear of the Jeep, which I will also upgrade with a rear Currie axle assembly (still deciding between the Dana 44 or HP60). Genright has a transmission crossmember kit that will allow me to drop the skid plate without also having to drop the transmission / transfer case and allow for their Belly-up skid plate which can give a few extra inches of ground clearance. That kit will likely be added after I replace both axle assemblies but before I install front and rear driveshafts from Adam's Driveshafts. After all of this, I'll bump up to 35" tires and because of that, will likely upgrade to the big brake kit from Black Magic Brakes to make sure I can come to a stop on those steep inclines & declines with the added weight of everything.

This is the biggest chunk of what I'm planning for, but I'll also be adding new bumpers, tube fenders, tire carrier and a variety of other upgrades, but I won't post about those until later when I'm closer to actually tackling those. The general plan is work front to rear taking care of the suspension and drivetrain and then rear to front with the more cosmetic upgrades and possibly finish with a supercharger if I want the extra kick, but I'm not sure about
that one quite yet.

Will all of this be overkill for me? Yes. But will it be a blast to take offroad? Also, yes.

Looking forward to a year of bad but really fun financial decisions!

Here's a few pictures of my trip a few months ago to Hot Springs Offroad Park to show how she currently looks:

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It's been a while since my initial post, but I've been replacing my stock front Dana 30 with the Currie high pinion Dana 44 as well as the control arms, track bar, shocks, and springs. My weekends have been pretty stacked, so I haven't been able to make as much progress as I'd like, but progress is progress. This is also my first time tackling anything this involved, so I'm learning as I go. Here's the progress so far.



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Since my last post, I've finished up the front axle swap, taken out the rear Dana 35 with the help of my old man, replaced my old headlights with some KC Gravity LEDs, and fixed some starting issues by replacing my battery wiring harness with JeepCables' Big 7 Kit. Next on the list is to add brakes to the new Currie 44 rear axle since it does not come with any brake components to include hard brake lines. I was going to reuse my old drum brakes, but after seeing how worn and dirty they are, I've decided to buy a new set. I'll also need to do my own hard brake lines since the Currie axle does not have the differential breather hose in the same location, meaning that I can't mount the block for the brake line in the same spot without drilling and tapping a new hole in the axle tube (which I'd rather not do). I'll play around with the flexible line's orientation and try to mount the block to the upper control arm mounting bracket since that would only need a drilled hole with a bolt / washers / nut to hold it in place. As per usual, here's a photo dump:

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Since my last post, I've finished up the front axle swap, taken out the rear Dana 35 with the help of my old man, replaced my old headlights with some KC Gravity LEDs, and fixed some starting issues by replacing my battery wiring harness with JeepCables' Big 7 Kit. Next on the list is to add brakes to the new Currie 44 rear axle since it does not come with any brake components to include hard brake lines. I was going to reuse my old drum brakes, but after seeing how worn and dirty they are, I've decided to buy a new set. I'll also need to do my own hard brake lines since the Currie axle does not have the differential breather hose in the same location, meaning that I can't mount the block for the brake line in the same spot without drilling and tapping a new hole in the axle tube (which I'd rather not do). I'll play around with the flexible line's orientation and try to mount the block to the upper control arm mounting bracket since that would only need a drilled hole with a bolt / washers / nut to hold it in place. As per usual, here's a photo dump:

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You may want to tie off that fuse somewhere. There should be enough cabling to zip tie it to the grill support. I just did this in my build thread. I don't love that solution for a solid mount — but I'd be careful with 12V lugs just flopping around...

Axle looks beautiful!
 
You may want to tie off that fuse somewhere. There should be enough cabling to zip tie it to the grill support. I just did this in my build thread. I don't love that solution for a solid mount — but I'd be careful with 12V lugs just flopping around...

Axle looks beautiful!

Thanks for the reminder! I've got it zip tied for now until I can come up with a permanent solution. I'm definitely surprised with how well built they are!
 
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Thanks for the reminder! I've got it zip tied for now until I can come up with a permanent solution. I'm definitely surprised with how well built they are!

It's a great cable set. Just try to be helpful as an outsider if I see a potential problem for a fellow Jeeper! I'm thinking to weld a tab to my grill supports... but that'll be after about 50 other engine bay changes...

So I just zip tied it up there for safety to wait for a better solution (welded tab).

I tried to use some tubing I had on-hand that was too large diameter for the grill guard supports. So, the right size tubing with tight zip ties could be a perm solution, too.
 
Now that I've finally had a few weeks at home, I've been able to make some pretty decent progress. I have the rear axle mostly installed, but I still need to mount the bump stops, get a good alignment, and finish out the new brake lines. I also took out the transfer case and installed a JB Conversions SSYE, and plan to get it mounted back to the transmission today when I get home, along with a Savvy cable shifter.

I ordered a UCF extra clearance skid last week, but it still hasn't shipped, so it'll give me time this weekend to do some clean up work and tie up some small stuff that I've been ignoring for these larger tasks. Next on the list is a new rear driveshaft, which I'll have to wait to order until I can get the tummy tuck done, but that's (hopefully) a fairly easy install that I can get done within a few hours.

Anyway, here's a photo dump:

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Novak Conversions Jeep Wrangler TJ radiator