Novak Conversions Jeep Wrangler TJ radiator

Project Cargo Shorts - 2006 LJR

Abendage

TJ Enthusiast
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Supporting Member
Joined
Feb 21, 2021
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375
Location
Colorado
Figured I'd post up a build thread before I start phase 2 of my build.

Backstory: I've owned my 99 TJ since September of '98 and it has been through countless builds finishing its prior life on 40's, stretched, etc. I flopped it in 2007 and sold the axles out of it and it sat for 11 years. In 2018 I got it running again and back to a normal size, stock wheel base, 35's, etc to use as a family wheeling rig. We used it sparingly, but I was bored with it. I wanted something more fun to drive, so I started collecting parts to LS swap and to also do a TJ-6 stretch on it as I've always wanted an LJ. As such, I always kept an eye open on LJ's for sale. Come January of 2021 I found a super high mileage, but otherwise beautiful, one owner LJR from New Mexico, perfect candidate for an LS swap with 250k on the clock. I have always wanted my TJ to be my son's first car, since, while technically it was my 4th car, I bought it when I was 16. Sounded like a perfect excuse to leave that how it was and to buy an LJR to build my dream Jeep for me so I loaded up the truck and off to New Mexico I went.

Day 1:
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I brought it home and slowly started doing a few small things like cleaning up the back end, new tail lights, MoRyde tailgate support, license plate bracket, etc.

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I about had all the parts gathered for the LS Swap, but I realized I had no desire to do an engine swap and everything else I had planned in my 2 car standard sized garage. My property had a 40x60 pole barn on it built by the previous owner, so I figured no time like the present to concrete/finish it to turn it into the shop like I always wanted. So the Jeep got put on hold for a little bit to finish the shop.

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Shop project complete:

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Now that the shop is done, time to get back to the build. First order of business was a Savvy 1.25" body lift, Savvy gastank skid, Crawltek rear bumper and the "butt crack" frame mod:

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Now it was time to get serious. Out with the old:

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I was really terrible about documenting the swap, I had no intention of doing a build thread at the time and it took me about 18 months to do it with work/family/other projects/interests. During this period I swapped in a LQ4, 4L80 and also installed Nemesis highline fenders. Figured it'd be a good time for the fenders to locate all the under hood accessories. Here's a couple pics that i did manage to get.

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Now it was time to get a little bit of height on it and get it on the trail. I had some spare OME springs sitting around from playing with spring rates on the TJ, so I installed those along with Savvy aluminum control arms and UCF Aluminum Skid Plate and Aluminum Engine skid. Due to the length of the 4l80 it would have taken significant floor mods to get the 241OR high enough to run a flat skid , so I had to settle on their 2" version, which was still a considerable gain over stock. I also got a screaming deal on a ShittyBilt winch (sub $300) so that's what I threw on there with a Motobilt front bumper. (I had not yet been introduced to Flux yet, unfortunately). Also switched to a Swayloc sway bar.

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Time to get on the trail, somewhere on Metal Masher I believe:

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Elephant Hill:

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That's more or less where its at today, I've done some painting/powder coating, built a trunk, etc.

Trunk:

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Now, I'm ready to start Phase 2. Here's the list for phase 2:

Flux Offroad Rockers and Corners - received already, hoping to have finished tomorrow.
Switch to Currie 4" springs and go to 37" tires with Coyote internal beadlocks
JK Rubicon axle swap with 4.88's - I already have the axles and well aware of the downfalls of this swap, for me I think the benefits outweigh the compromises.
Outboard front and rear shocks
Hydro assist

Other than the Flux items, the rest will be waiting a little bit. I'm getting married in October and we're using the shop as the venue, so I'm pretty sure my wife would be pissed if I ripped the axles out of the Jeep and had it sprawled all over before that.

I did order the tires already though so i can trim the rear and start setting bumpstops. Here's a teaser:

Screenshot 2025-08-23 133623.png
 
Last edited:
Rockers are pretty much done. Not sure what I’m going to do with the front flare. I didn’t want to cut the stainless portion of the rocker to make the full flare fit, so I shortened the flare to sit above the rocker. It isn’t my favorite, so not sure it will stay.

Rear corners should be done tonight.

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I was only able to get one corner done last night. Took me longer than I care to admit to get the rocker/corner gap to a reasonable amount. It also took me way too long to find bolts for the tail light and gas filler in the abyss that is the spare hardware drawer. Then there’s that I’ll be replacing anyways after I went to the hardware store this morning to get the correct button heads.

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Nice rig,what did you use for manifolds and y pipe?

I used Camaro manifolds and cut the flanges off and welded v-bands on them. I used a prefab y pipe and a builder exhaust kit. 2.5” from the manifolds to the y and 3” after that. This was the initial version, it stayed pretty much the same, but I changed a few angles to clear the driveshaft and added a flex joint in between the manifolds on the portion that runs in front of the oil pan.

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You can barely see the v-band in this pic. Sorry I was horrible about getting pics during the swap.

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Novak Conversions Jeep Wrangler TJ radiator