Novak Conversions Jeep Wrangler TJ radiator

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

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As for the adjustable spring seat - very cool! That’s one advantage that coilovers generally have.
Except with coil-overs, you can't walk up, reach over the top of the tire with a ratchet and a 5/8" Allen bit socket and crank them up or down in a few seconds or so with the weight on the axle.
 
Except with coil-overs, you can't walk up, reach over the top of the tire with a ratchet and a 5/8" Allen bit socket and crank them up or down in a few seconds or so with the weight on the axle.

No, you sure can’t. The only thing that could beat that would be hydraulic preload adjusters like on some motorcycles and snowmobiles.
 
If we're encouraging [dumb] questions I am good at that!!

What are the piano hinges for? For installation/storage ease or to make it somewhat "adjustable" to fit in bigger stuff? Probably the former since it is bespoke to the specific stuff you intend to carry?

Questions are always welcome.

Everything being done to this jeep is for a purpose and Blaine has put a lot of thought into the details and execution despite my vague explanations of what/how/where I want to use the Jeep. But what he is doing more than adequately covers for everything I will do with the Jeep. There are some very nifty solutions all over the vehicle solving specific problems. I have tried my best to do justice to the work that Blaine is putting in. Although this build thread is more for myself in many ways, some responses/participation would make it much more enjoyable.

The "problem" of rear storage in a TJ is something that not been addressed before to the level being done in this build, atleast this to my knowledge. I had looked at every single thread on this forum, Jeepforum, Wranglerforum, ROF .. and also looked at every single solution out there (Genright, Bestop, Hooke, Tuffy, Diabolical ..) and everything I saw had compromises and some of the, with really bad compromises. Permanent shelves like commercially available restrict you in more ways than one and force you do to things a specific way which may not be ideal. Blaine's solutions here are much better thought out in terms of usability and convenience and has put in a ton of effort to maximize the storage/functionality while still keep it looking clean and easy to take everything out quicky if desired.

The piano hinges are there so that the shelf setup can fold and be out of the way if there is a need to use the rear space of the tub.

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Are you worried about losing visibility through the back windows? Maybe I just think that's essential because I don't have a mirror on the passenger side.

Rig has a rearview camera mirror (and a dedicated backup camera system) .. see a few pages back.

I don't have any deep questions, but out of curiousity - are you leaving the rear sport bar padding in for aesthetics or is it just not worth removing?

I like the set up a lot and wish I could delete my rear seat but might try to adapt some ideas with just my LJ trunk space until my kids are older. What size are the water jugs? Have you tried lifting them in and out full? I'm sure it's doable, just curious if it's at all irritating since the angle your body will be at will be awkard.

I see no reason to remove the padding. Water jugs, see info below.

How'd you find water jugs that perfectly match the cooler?? I like seeing the cooler with everything around it. The form factor seems pretty efficient. Still waiting for Jeremy to upload pics of his to decide which one to go with 😉

The large water jugs (5gallon/20L) are stupid heavy. These are the smaller 10L Scepter ones which are much more easier to move around. Good fitment is due to Blaine's thoughtfulness in looking at overall picture + thinking about usability as a whole.
 
Questions are always welcome.

Everything being done to this jeep is for a purpose and Blaine has put a lot of thought into the details and execution despite my vague explanations of what/how/where I want to use the Jeep. But what he is doing more than adequately covers for everything I will do with the Jeep. There are some very nifty solutions all over the vehicle solving specific problems. I have tried my best to do justice to the work that Blaine is putting in. Although this build thread is more for myself in many ways, some responses/participation would make it much more enjoyable.

The "problem" of rear storage in a TJ is something that not been addressed before to the level being done in this build, atleast this to my knowledge. I had looked at every single thread on this forum, Jeepforum, Wranglerforum, ROF .. and also looked at every single solution out there (Genright, Bestop, Hooke, Tuffy, Diabolical ..) and everything I saw had compromises and some of the, with really bad compromises. Permanent shelves like commercially available restrict you in more ways than one and force you do to things a specific way which may not be ideal. Blaine's solutions here are much better thought out in terms of usability and convenience and has put in a ton of effort to maximize the storage/functionality while still keep it looking clean and easy to take everything out quicky if desired.

The piano hinges are there so that the shelf setup can fold and be out of the way if there is a need to use the rear space of the tub.

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View attachment 599857
Cool!! That is smart, so you can put something big in there without a bunch of work.
Rig has a rearview camera mirror (and a dedicated backup camera system) .. see a few pages back.
Sorry I should've been more clear, I meant the side windows in the back. E.g. when checking blind spot changing lanes on the highway. I always do a quick lookback on the passenger side... But again that might just be because I don't have a mirror there. I guess I don't remember how big the blind spot is with it anymore
 
Questions are always welcome.

Everything being done to this jeep is for a purpose and Blaine has put a lot of thought into the details and execution despite my vague explanations of what/how/where I want to use the Jeep. But what he is doing more than adequately covers for everything I will do with the Jeep. There are some very nifty solutions all over the vehicle solving specific problems. ...

What I have been appreciating along the way is the identification and use of multiple previously unusable spaces in the cargo area. The whole space between the B and C pillars can be utilized with racks and shelves. The small shelves near the headrests, the now enclosed pocket at the front of the wheel wells, and the area up between the rear speakers are all useful now. The main shelf doubles the cargo area, but it can still be folded up for larger things when needed. This entire system is very efficient.

Years ago I modified a Harbor Freight cargo rack to fit behind the seats. It was inefficient, heavy, and poorly attached, but worked well enough for a long time before I ended up removing it last year with the intention of doing better. Like you, I have never liked the available options for reasons of both function and aesthetics. There are many ideas in Blaine's rack that I will be incorporating when the time comes to rebuild mine.
 
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Everything about this build is a special. Honestly, I remain speechless as I observe. I have all sorts of ways of organizing the jeep storage but none of it is thought out at all. Keep up the amazing work 🇺🇸
 
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What I have been appreciating along the way is the identification and use of multiple previously unusable spaces in the cargo area. The whole space between the B and C pillars can be utilized with racks and shelves. The small shelves near the headrests, the now enclosed pocket at the front of the wheel wells, and the area up between the rear speakers are all useful now. The main shelf doubles the cargo area, but it can still be folded up for larger things when needed. This entire system is very efficient.

Years ago I modified a Harbor Freight cargo rack to fit behind the seats. It was inefficient, heavy, and poorly attached, but worked well enough for a long time before I ended up removing it last year with the intention of doing better. Like you, I have never liked the available options for reasons of both function and aesthetics. There are many ideas in Blaine's rack that I will be incorporating when the time comes to rebuild mine.

When we were discussing the rear storage earlier, Blaine suggested I think about Bulldawg mfg hardtop that has side windows that open (1st pic below).

I chose not to do it, partly due to the 3600+ cost, but also because my idiot dumbass could not fully understand Blaine's vision/foresight and him being able to utilize what would be otherwise dead space with his mad fab skills. Imagine a gridwall in highlighted green area in 2nd pic .. you go to camp, open side windows and easy access to all the small stuff you need. The bigger stuff is accessed through the tailgate as normal. Even though I did not choose that top .. Blaine is still maximizing every bit of utility in the back.

Don't get me wrong, I am super happy with what I have in the orange jeep. Everything Blaine has touched has been magical and I consider myself fortunate/lucky to be working on this build to make my dream jeep.

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When we were discussing the rear storage earlier, Blaine suggested I think about Bulldawg mfg hardtop that has side windows that open (1st pic below).

I chose not to do it, partly due to the 3600+ cost, but also because my idiot dumbass could not fully understand Blaine's vision/foresight and him being able to utilize what would be otherwise dead space with his mad fab skills. Imagine a gridwall in highlighted green area in 2nd pic .. you go to camp, open side windows and easy access to all the small stuff you need. The bigger stuff is accessed through the tailgate as normal. Even though I did not choose that top .. Blaine is still maximizing every bit of utility in the back.

Don't get me wrong, I am super happy with what I have in the orange jeep. Everything Blaine has touched has been magical and I consider myself fortunate/lucky to be working on this build to make my dream jeep.

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I'm thinking about trying to do those side access windows in my beater Xterra. I don't love everything dirt lifestyle does - but something like the access doors on his discovery.
 
I'm thinking about trying to do those side access windows in my beater Xterra. I don't love everything dirt lifestyle does - but something like the access doors on his discovery.

Stopped watching that channel after that BS long arm video a long time ago.

Do they make aftermarket windows for the Xterra that open that way?
 
When we were discussing the rear storage earlier, Blaine suggested I think about Bulldawg mfg hardtop that has side windows that open (1st pic below).

I chose not to do it, partly due to the 3600+ cost, but also because my idiot dumbass could not fully understand Blaine's vision/foresight and him being able to utilize what would be otherwise dead space with his mad fab skills. Imagine a gridwall in highlighted green area in 2nd pic .. you go to camp, open side windows and easy access to all the small stuff you need. The bigger stuff is accessed through the tailgate as normal. Even though I did not choose that top .. Blaine is still maximizing every bit of utility in the back.

Don't get me wrong, I am super happy with what I have in the orange jeep. Everything Blaine has touched has been magical and I consider myself fortunate/lucky to be working on this build to make my dream jeep.

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View attachment 599971

I have definitely settled on that hard top when I finally have the funds and drive to
Replace the softop
 
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It's time for the crossmember!

Here is the the finished piece - ready to drill and mount into the rig. It's a thing of beauty. This crossmember has several design elements from Blaine that are absolute treats ...

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If you look at the TJ frame, it angles near the skid plate ..

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The cross member follows the shape of the skid. When Blaine bent the cross member and designed the flanges, he cut the ends at two angles, one to follow the angle of the frame and then the second on the end for the mounting flange so it would end up parallel to the eventual bottom flat section of the skid.

A straight edge on the ends, left side and right side , showing how even things are side to side.


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He then made the matching frame side flange that is nicely welded to the frame .. and 3 bolts connect them together on each side. This pic below shows the final installation showing how everything looks at the finish, but of course, getting everything situated exactly where they needed was not trivial.


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This was the process to get to the final pics above ..

The crossmember was first bolted up to the transmission mount with the mock up crossmember piece holding it up. This was used to figure out the height for the final setup, and it looked like shims totaling about 3/8” in thickness were needed to put the case up where it needs to be height wise. Blaine split that into 2 pieces each 3/16” thick, one on top of the trans mount and then one under the trans mount. These are shown with green arrows below. The reason to split the shims was the studs from the 2-part trans mount from earlier would have been too short if all the shim was at the bottom.


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After the shims were welded in, the crossmember was installed to correct height again. Then the frame brackets were clamped in place, tack welded, and then drilled in place through the holes in the flange on the crossmember.

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One very nice piece of detail work on the recessed holes in the crossmember. Blaine sized the holes were by fitting impact socket inside them to ensure that no special tool would be needed to remove the nuts on the transmission mount. Blaine cut pieces of tube, stuck them in the holes, welded around them and then ground them flat. Below is the end result .. the amount of work that went into making what seems simple from the outside just blows me away.

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With all the care taken to make sure the heights are exactly what they needed to be, we ended up with ample space at the top of the Atlas case (yellow arrow) and no chance whatsoever of the t-case contacting the tub. You can fit your entire palm in there easily.

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After finishing all this up, Blaine started on the belly skid .. and that will be a separate post since the spectacular work there deserves it's own post!


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So sick
 
It's nice to see the final finished piece inside the Jeep. I am really pleased with how this project turned out, including the super functional phone mount (not visible in this pic) near the A-pillar.

This is what you see from the driver's seat. Careful eyes will notice how Blaine angled the trans temp gauge a little bit towards the driver's seat.

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A more head-on close-up.

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Blaine is working on cleanly integrating the SSV amp and the USB power supplies at the back.

I have a NSE… stands for Non Sexual Erection
 
I like the rod vs the laser cut mollie panel. It seems like it would be way easier to attach items thru a large square and the ability to see everything is waaaay better. Like closet maid for our jeeps!
 
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@psrivats, having spoken to you a little about this build and having gone thru a deep q&a with @mrblaine when I asked him if he would work on my TJ, I am assuming you have a number of different user scenarios where weight is a factor. In fact, looking at the pics you have posted, it is clear that the placement of your specific items are very purpose driven with weight being the main factor. Question is, @mrblaine alluded to adjustable spring seats which begs my question, how many different weight configurations do you have in mind when using your TJ? What is the heaviest you think you would be hauling? Would there be settings based on which configuration you are using that day/weekend/trip? If so, and i am clear the 2 of you have thought that far and deep, that is pure playing chess whilst the rest of us are playing checkers!
 
Wire grid lets you do stuff like this too :)

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I noticed that earlier. That stuff is light, strong and easily modified. The only issue I'd note in working with it is the galvanizing makes welding either dangerous or a little more tedious. You need to remove the zinc coating and still should wear a respirator and work in a very well ventilated space to avoid both acute and long term health issues.
 
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I noticed that earlier. That stuff is light, strong and easily modified. The only issue I'd note in working with it is the galvanizing makes welding either dangerous or a little more tedious. You need to remove the zinc coating and still should wear a respirator and work in a very well ventilated space to avoid both acute and long term health issues.
It is not galvanized. It is store display gridwall. Generally has a very light powder coating over bare steel or one of the electro paints. If I was using hog wire or horse panel, then I'd have to deal with the zinc which is why I'm not using hog wire or horse panel.
 
Question is, @mrblaine alluded to adjustable spring seats which begs my question, how many different weight configurations do you have in mind when using your TJ? What is the heaviest you think you would be hauling? Would there be settings based on which configuration you are using that day/weekend/trip?

I think you are farther ahead than I am at this point with these questions.

I do not know, but I am looking forward to figuring it out with Blaine's help and guidance.
 
I think you are farther ahead than I am at this point with these questions.

I do not know, but I am looking forward to figuring it out with Blaine's help and guidance.

I am likely oversimplifying a bit, but my mind is circling around indexing based on shock travel. The zero index is the baseline rig (whatever the consistent load + human is) since it will only ever get more weight in it, anything else moves the spring perches toward each other to get the shock travel back where it was designed to be affording for the spring's collapsed size. I can't wait to see how Blaine designed it and all the other pieces involved!
 
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Novak Conversions Jeep Wrangler TJ radiator