Novak Conversions Jeep Wrangler TJ radiator

What did you do to your TJ today?

So I reached out to a couple people including mrblaine and asked around. Consensus was weld it where it touches. But that's about when I realized the spring perch was crooked and the factory welds at the tube to C were a bit lumpy in spots causing interference. Once I did some filing/grinding the truss fit flush against the spring perch and there was a sizeable and even gap to the pumpkin on each side.

::edit:: I misread your question. I left them stitched. I figured less potential warping, and if one weld fails it won't tear across all of them.

Long answer, but no, I didn't. The only place I ended up welding to the pumpkin is the upper CA mount ears. I preheated them with a map torch but I think with their size and surface area they wick heat pretty fast, could only get them to 300°f. Welded and wrapped right after with a fiberglass blanket. Just used regular 030 mild steel wire with the feed and gas turned up. There was a lot of sputtering I assume from the cast iron and I'm sure a good bit of porosity in there, but with the amount of fill I did all around I think it's probably solid enough. Time will tell.

I think people are often afraid to post their welds since welders are the judgiest motherfuckers around but I ain't scared. I'm very much an amateur. Open to suggestions too, of course.

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This morning I finished hacking off the front control arms. Going to sand everything down, weld on the new brackets, then paint the front half of the frame. Got a new rear main seal and oil pan gasket while I'm in here. Probably give the oil pan a coat of paint. Tempted to do red since I have the engine paint here. All of that oil mess appears to be from the valve cover, btw. I have a new one of those gaskets as well.

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Your welds don't look bad, Preparation is just as important as welding. Pretty welds aren't necessarily strong & ugly welds aren't necessarily weak. Stich welding it was a good idea to prevent warpage & it will alleviate cracks from creeping along a full length weld. However a sudden crack causing failure in one stitch weld can cause the other welds to undergo higher levels of stress causing them to crack as well. It's highly unlikely this type of failure will occur in this application though. Keep in mind that welding can cause stresses in the parent metal surrounding the weld (Heat Affected Zone). Just a bit of welding knowledge to keep in your pocket.
 
Ha, @AndyG will win that every month!!!!! Ask @tr21triton he has seen Andy in action!!!!!!! 🤣 🤣 🤣

This is just like John.

Some hunters captured a real female big foot down here...And the state department of natural resources got a hold of it and they were just making the biggest deal and said they had to keep the DNA alive-

I was telling John about it and that they wanted somebody to breed with it and it paid $15,000.

He asked “ Do you think they will take payments?”
 
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Bypassed my heater core today, should tell me if it’s for-sure my heater core causing my coolant overflow level to slowly drop.
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Looks basically factory hey? NOT. :ROFLMAO:
Anyone have any idea what I could cap the ports off with that I could pick up from the hardware store? Don’t wanna tap them out.

Cap the ports on the heater core that come thru the firewall?
 
Bypassed my heater core today, should tell me if it’s for-sure my heater core causing my coolant overflow level to slowly drop.
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Looks basically factory hey? NOT. :ROFLMAO:
Anyone have any idea what I could cap the ports off with that I could pick up from the hardware store? Don’t wanna tap them out.

Welcome to the club, unfortunately😢
 
Busy Sunday...replaced the dash speakers and installed new ones with dash-pods. Also replaced the sound bar speakers. Then the big propject, I installed a new double din radio. Lots and lots of back and forth getting the alignment of the new radio to fit with the new dash kit. I had to create new screw locations for the left and right bottom screws also. Very happy with the results. only thing left is creating a place to store the iphone and have it connected to USB in the back of the radio.


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This is just like John.

Some hunters captured a real female big foot down here...And the state department of natural resources got a hold of it and they were just making the biggest deal and said they had to keep the DNA alive-

I was telling John about it and that they wanted somebody to breed with it and it paid $15,000.

He asked “ Do you think they will take payments?”

Found her
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Got the 3” exhaust installed recently.

Installed the boost controller wiring, boost map sensor, and boost solenoid yesterday. This helps me go into boost sooner bc the internal waste gate was partially opening too soon.

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Where did you get that a-pillar setup with the gauge pods?

TIA.
 
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Over the weekend, I finished the Genright body mount lift kit installation.

Compared to the tops of the OEM brackets I'm measuring closer to 1.5” of lift than 1”, even more than 1.5” on the front set of mounts. The Jeep had a 1” plastic puck lift before and definitely sits higher than before. The 1” puck on the radiator body mount has 1/4”+ of slack. Savvy 1.25” lift inbound to replace the remaining plastic 1” pucks.

The radiator fan is now hitting the bottom of the shroud so I’m swapping the existing 0.6” motor mount lift blocks for a set of the MORE 1” motor mounts.

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Got the 3” exhaust installed recently.

Installed the boost controller wiring, boost map sensor, and boost solenoid yesterday. This helps me go into boost sooner bc the internal waste gate was partially opening too soon.

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What is your dome pressure? How mush boost you getting on the 2 step?
 
Replaced the upper & lower steering shaft and the steering gear. OMG, the jeep handles like a Porsche now...ok, not really but what a giant improvement. Steering was sloppy and just not very responsive, now it feels brand new.

On a separate note, I also snapped one of the bolts to mount the steering gear to the frame. Apparently my torque wrench is crap and stopped working cause I just kept going and going until it snapped. My fault, I knew it was too much but kept thinking the torque wrench is going to click any moment now. Huge thanks to @mrblaine for hooking me up with a new bolt.
 
What is your dome pressure? How mush boost you getting on the 2 step?

I just googled dome pressure since I had never heard of that term. I only have the ability to read MAP and boost. Apparently dome pressure is different so I don’t know what it is if I’m being honest. I’d be happy to learn more about it (and its significance) if you’d be willing to share.

I’ve only driven the new set-up in town but it goes to about 5 psi in the low setting that I programmed it to. The controller won't prevent me from over-boosting on the highway which is a concern, but it helps me boost sooner and hold boost in town by removing pressure on the actuator spring (and opening the WG) until the solenoid valve opens via the controller setting.
 
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Novak Conversions Jeep Wrangler TJ radiator