Novak Conversions Jeep Wrangler TJ radiator

Nothing I need, everything I want (2005 TJR, impact orange)

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psrivats

runs loose!
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This build thread is for a new (to me) Jeep, an orange 2005 TJR. I want to preface this build thread with a few thoughts about the "Why" of it, and I hope that the "How" of the build thread will follow naturally.

Folks here that know me will understand that I tend to lean towards the philosophical side. There is a feedback loop that is continuous in our lives and we are all peripherally aware of it even if not always conscious about it. What one calls personal philosophy is simply our crystallized thoughts over time, honed by our life choices, by our life experiences and also shaped by the influence of people we surround ourselves with. From my personal experiences, I can say if we carefully think through the how/why of what we do, it will raise our general awareness and will put us on a path towards better choices and more effective life decisions. Even with this feedback we sometimes don't always do the right things. We may think we know more than we really do, sometimes we get caught in the moment, we get caught with time pressure, we get caught with emotion and so on. It is also not always immediately apparent that we did not make the right choice, but eventually deep inside you DO realize it .. and whether or not you accept it to yourself and/or the outside world, and whether or not you course correct to go where you wanted to go originally is an entirely different story. Over time, this feedback when it has been nurtured enough will immediately tell you right vs wrong and there will be no question about what is the path to take when you reach a decision point.

This build thread is my course correction to take me where I want to go. And I want to get there following some specific ideologies that I have come to respect and appreciate very much.

I recently sold my old black TJR. "Why a new build? Why can't you continue or course correct on this path with the old one?", you may ask. Two reasons (1) The black jeep was liked and it went to someone I know whose needs are more than adequately met by that jeep's build and design points and you will hopefully continue to see it on this board (2) To get what I am wanting now, It was also simply easier to restart with a new jeep and specifically with this jeep, I want to support a specific group of people whose philosophies and life paths really resonate with mine.

This thread build is started to both share my learnings and showcase the work that is happening. I am fortunate to be in a position in life to be able to restart this way and it's exciting to see what is ahead. I am also well aware that my needs are fully met with a stock TJR; this is a dream build for me in more ways than one and hence the title.
 
What good is a build thread without photos? This is the jeep the day we bought it. TJR, manual transmission, 8x,xxx miles, California vehicle all its life, and fully stock in all things that matter.


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I bought my previous Jeep ~7years ago and I did all the things that typical new Jeep owners do to make it my own. The early days are still relatively fresh in my mind and it was a highly enjoyable time where I learnt about the platform and saw the community around Jeeps. Modifications were exciting, and reading about what other people were doing, even more so. Assuming (incorrectly, looking back now with the magnifying glass of experience) that I understood what I wanted, I started a journey of lifts/shocks/suspension. The build eventually became a hodgepodge of many things and ideas, some good, some bad, some outright dumb. The jeep still took me places, eventually after fixing certain things with generous help from knowledgeable folks, it was even enjoyable to drive, and it was more than capable for what I needed .. but it did not fulfill that desire of a dream jeep the way that the heart has been wanting.

It took me some time to come to that realization, some more time to understand why, and then some more to understand what really I was searching for. But the answers eventually became clear.

Not too far long ago, and from some specific and singular circumstances whose details are not relevant for this thread, I very clearly realized that shocks really matter and they matter a whole lot when it comes to enjoying the classic 4x4 we love here. That realization opened my eyes to think about many other things that will read like hyperbole if I write about it, despite the absolute reality of the facts .. so I will just say that when I had this epiphany, it really made me pause and think about what I thought I knew versus how much I actually knew. It was very formative to go through this process, because you start comprehending things in a very different way afterwards both with respect to technical stuff and also about people.

The people part is important - we are shaped by the company we keep and it is imperative that we choose carefully who we associate with. There are certain companies whose philosophies simply are an 180 from how I think and operate, run by folks who are seeking something much different than me in their lives. And there are people who believe in doing things right, simply because of their beliefs and value systems, despite how hard it is to operate that way in today's world where success is measured in terms of assets owned and values secondary to profit. There is a certain kind of joy (not easily expressed in words) that comes from working with people that are masters at their craft, who take pride in doing things right and care very deeply about the quality of their work and the happiness of the end user.
 
The orange Jeep is going to be built by none other than @mrblaine.

This build is a realization of a specific dream of building a jeep that my heart desires and I am very thankful that he agreed to help make that vision come true. The previous Jeep was an answer to a different kind of question and I learned a lot from owning it, getting it built, trying to solve the problems that came up and I am happy for that learning. But now, I simply have better clarity in terms of what I am searching/seeking and the question I am asking this time is much different. I did not get this clarity all by myself .. it was borne out of the many many thoughtful conversations I had with Blaine over time after my shocks epiphany, his patient explaining of things technical and non-technical, and his guidance towards making me think more critically about what I really wanted.

The goal is to have an exemplary jeep on 35s with properly tuned shocks front and rear, and everything else around to make those happen - with generous sprinkles of "while I am in there .." and "why the heck not?" all over. So you are going to witness the build of a mid arm suspension, BBK/hydro assist steering, Rubicrawler + Atlas 2:1 combo, raised belly and raised body mounts, rockers and corner armor.

Do I need any of this? Nope, but that is not the point of this build :)

All good things have a genesis, and here it is for the Orange jeep. More pics and comments to follow ...

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Sounds like a dream build! Sticking with the manual?

Thanks, and good question. This jeep will be getting a trans swap. A rebuilt 42RLE (along with the the Rubicrawler) will be going in soon.

The grey stuff you see in between is the 3Bond sealant from Mopar (@jjvw wrote about it in his build thread very recently). Blaine said it's the best product for that application.

And yes, this jeep is a dream build in more ways than one.

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Remember the forged alloy wheel experiment from a while ago? Here they are with 255/85/17 MT Baja Boss AT tires wrapped around them. 35s are big.

Wheel specs for those interested - 17x7.5, 5x5.5 pattern, 4" backspacing, center bore 4.25" to accommodate Yukon big hub kit. Yep, not doing down the vibration saga again, had enough of that crap. Blaine will be doing his magic to mate the Yukon big hub kit and his BBK together. While that sounds simple, it is nothing but - there are lot of small details to take care of. More details and photos on this later in the thread.

When Blaine swapped the manual trans from this into my older black jeep, he was able to fix the vibration problem for good. He found that the 241 t-case was touching the tub and also couple other spots where the tub/frame were solid contacted accidentally. For those that can recall the saga, a large portion of the vibes I had somehow went away when I put the rubicrawler in the older jeep (guessing something that changed the resonance vibration) and then the big hub kit went in which made the vehicle nice to drive on the highway without annoyance. But there still was small portion of the vibration that still remained that no one local to me could ever solve. Blaine found the source of the problem and fixed it for good. It made me very happy to sell that black jeep telling the current owner that that vehicle was fully vibe free.

I can't wait to see these wheels mounted on to the vehicle eventually.

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For those that can recall the saga, a large portion of the vibes I had somehow went away when I put the rubicrawler in the older jeep (guessing something that changed the resonance vibration) and then the big hub kit went in which made the vehicle nice to drive on the highway without annoyance. But there still was small portion of the vibration that still remained that no one local to me could ever solve. Blaine found the source of the problem and fixed it for good. It made me very happy to sell that black jeep telling the current owner that that vehicle was fully vibe free.
Shame on me for not paying more attention. We've known for a long time that the Rubicrawler is not made to the same spec as the tail housing on the 42RLE with regard to the transmission mount location. We always have to space the stock mount down with a raised belly skid to raise the corner of the t-case back up off of the skid. But yes, you are correct that the black one is now 100% vibe free.
 
Those rims are going to look great! Love the old school look of them. It's also awesome to start with such a clean unmolested Jeep too.
 
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Remember the forged alloy wheel experiment from a while ago? Here they are with 255/85/17 MT Baja Boss AT tires wrapped around them. 35s are big.

I was wondering what the heck happened to those wheels! I kept checking your old thread and started to wonder if you sold them or something and even checked out the Oregon craigslists to see if they were on there. :ROFLMAO:

Very excited to watch this build and that's a beautiful jeep you got there. And as always looking forward to seeing more of Blaine's brilliant work.
 
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I was wondering what the heck happened to those wheels! I kept checking your old thread and started to wonder if you sold them or something and even checked out the Oregon craigslists to see if they were on there. :ROFLMAO:

Very excited to watch this build and that's a beautiful jeep you got there. And as always looking forward to seeing more of Blaine's brilliant work.

A lot of effort went into those wheels to simply sell them on Craigslist. Most people on CL/FB simply don't have a good appreciation for things like that.

As for Blaine's work .. the level of meticulous planning and the execution is something really beautiful to watch.

He started with the front. The radiator was drained and pulled out, all the steering links and the trackbar were removed. Since the transmission is already out, it made it relatively easier to remove the stock frame side control arm mounts.



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Next, it was time to work on the front axle. The axle side LCA mount was cut out, and an Iron Rock offroad mount was welded on. You can see the tiny row of punched dots that are used to mark the location of the mount. It's a small detail but something borne out of practice and experience.

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Next, the track bar bolt and stabilizer bolt reinforcement plate were added. You can see the bend in the bracket to get them exactly at the angle needed to get it to sit perfectly. Aso notice the hardware .. Blaine is a walking encyclopedia when it comes to understanding what hardware to use where and nothing is chosen without purpose.


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Then, the factory cast control arm mount was removed and trimmed ...

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... and trimmed exactly where it needed to be when the truss goes on.

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As for Blaine's work .. the level of meticulous planning and the execution is something really beautiful to watch.

He works his canvas like a true artist! 🎨
 
Welcome back, Sri. Great project. Looking forward to you showing us Blaine’s work.

Although we all still liked you, it wasn’t quite the same while you didn’t have a TJ… 😉
 
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What tool was used to cut the front control arm mount off? I like how tight the cuts are to the axle tube...
 
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Novak Conversions Jeep Wrangler TJ radiator