Novak Conversions Jeep Wrangler TJ radiator

Adding a cabin filter on my 97 TJ

Jezza

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Hey Y'all, I just wanted to share the cabin filter I added to my 1997. I bought this thing with a bad heater core and changed it recently. When I took the hvac box apart I noticed a few things. Firstly on the 1997 the fresh air intake under the cowl is wide open and doesn't have the cover like the later ones do. Secondly the duct between that intake and the heater box is only sealed with some loose foam strip. Mine was very loose and the foam was all flat. Thirdly the ac evaporator had all kinds of garbage in the front. I also noticed that water has been entering from the cowl intake and down under the carpet causing the floor to rust. I had previously worked on a cabin filter box for my LJ, but it hasn't been a priority. I decided to finish the box and install it on the '97 to prevent trash from entering the duct system and to help keep water from freely entering the cabin. The cabin filter I used is from a Jeep Liberty and it uses two parts. I only used one part. The box base is solid and should prevent most water from getting into the duct until it's almost an inch deep. The filter does restrict the flow slightly, but I think the filtration is worth the reduction in flow. I did have to heat and massage the top slightly to get the cowl to fit back on flat. Mostly on the far outside and some in the center. I could change this in the design, but I don't care that much and don't plan to sell these or anything. I also had to cut off the part of the duct that sticks out above the cowl floor. I silicone the bottom of the filter housing to the cowl floor and screwed it down. So far it has passed the garden hose test, and hopefully it will keep most of the dust and tree bits out.

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Hey Y'all, I just wanted to share the cabin filter I added to my 1997. I bought this thing with a bad heater core and changed it recently. When I took the hvac box apart I noticed a few things. Firstly on the 1997 the fresh air intake under the cowl is wide open and doesn't have the cover like the later ones do. Secondly the duct between that intake and the heater box is only sealed with some loose foam strip. Mine was very loose and the foam was all flat. Thirdly the ac evaporator had all kinds of garbage in the front. I also noticed that water has been entering from the cowl intake and down under the carpet causing the floor to rust. I had previously worked on a cabin filter box for my LJ, but it hasn't been a priority. I decided to finish the box and install it on the '97 to prevent trash from entering the duct system and to help keep water from freely entering the cabin. The cabin filter I used is from a Jeep Liberty and it uses two parts. I only used one part. The box base is solid and should prevent most water from getting into the duct until it's almost an inch deep. The filter does restrict the flow slightly, but I think the filtration is worth the reduction in flow. I did have to heat and massage the top slightly to get the cowl to fit back on flat. Mostly on the far outside and some in the center. I could change this in the design, but I don't care that much and don't plan to sell these or anything. I also had to cut off the part of the duct that sticks out above the cowl floor. I silicone the bottom of the filter housing to the cowl floor and screwed it down. So far it has passed the garden hose test, and hopefully it will keep most of the dust and tree bits out.

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Will you make the STLs available to us?
 
Will it fit a 2004?

Not that one. The lid is the same, but the base is slightly different. This is the base I made for the 05. It screws right onto the cowl using the existing holes. I had to heat the top and form it to fit the cowl panel like the 97.
 

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^^ Just ordered it up ^^....Thank you for the link.

I think 3-D printing is awesome, and quite frankly need to get in the game with it.
 
Has anyone come up with a design for one that can be accessed from the cab? Or at least not requiring removal of the cowl? Both on my Jeeps are a tight fit and with the dust here a filter has to be replaced at least once a year.
 
Has anyone come up with a design for one that can be accessed from the cab? Or at least not requiring removal of the cowl? Both on my Jeeps are a tight fit and with the dust here a filter has to be replaced at least once a year.

The only in cab design I've seen on this forum is cutting and inserting filters into the upper central vents (behind the louvers).

I also have to replace mine 2x a year due to the amount of dust where I wheel. Once you've done it a few times, removing and replacing the cowl takes minutes which is very much worth it to me. I notice the airflow decreasing soon after installing new filters, so I'm going to begin testing lower MERV filters.
 
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Yeah it's not hard to remove the cowl, it's quick. Mine are just so tight I risk scratching the paint each time.
 
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So I got around to installing this version in my 06' LJ.

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I did have to modify it a bit by trimming one of the corners, (top left corner in the below picture) . Also, the screws provided aren't long enough. I had some screws laying around that I used. It was symmetrical to the opposite side. I also added some weatherstipping, as this kit didn't come with any.
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I did have some junk collected up in the cowl area, so glad I did this. I am however not too thrilled about having to remove the cowl to change out the filter, but honestly don't see how it can be done any other way. I don't really offroad, put a lot of miles on it, and it is normally garage kept, so it should last me quite a while. It did come with a 2nd filter, so that is nice to stay ahead of ordering them.

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So I got around to installing this version in my 06' LJ.

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I did have to modify it a bit by trimming one of the corners, (top left corner in the below picture) . Also, the screws provided aren't long enough. I had some screws laying around that I used. It was symmetrical to the opposite side. I also added some weatherstipping, as this kit didn't come with any.
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I did have some junk collected up in the cowl area, so glad I did this. I am however not too thrilled about having to remove the cowl to change out the filter, but honestly don't see how it can be done any other way. I don't really offroad, put a lot of miles on it, and it is normally garage kept, so it should last me quite a while. It did come with a 2nd filter, so that is nice to stay ahead of ordering them.

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The guy on eBay that makes the 3d printed version that’s more expensive says in his listing that the Chinese knocked off his design in assuming this is the one he’s talking about. I’m buying from the original innovator and USA based manufacturer because I hate the fact that the came in and undercut him on his own creation and his looks better too. Buy American.
 
The guy on eBay that makes the 3d printed version that’s more expensive says in his listing that the Chinese knocked off his design in assuming this is the one he’s talking about. I’m buying from the original innovator and USA based manufacturer because I hate the fact that the came in and undercut him on his own creation and his looks better too. Buy American.

It's not a knock off (duplicate) of his design. It's an IMPROVEMENT of his design, and it also looks to be INJECTION MOLDED ABS which it superior. I don't prefer Chinese products in general, but I got to give credit where it is due.
 
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It's not a knock off (duplicate) of his design. It's an IMPROVEMENT of his design, and it also looks to be INJECTION MOLDED ABS which it superior. I don't prefer Chinese products in general, but I got to give credit where it is due.

So superior it had to be modified to fit and the screws it came with were the wrong size 🫣
 
The guy on eBay that makes the 3d printed version that’s more expensive says in his listing that the Chinese knocked off his design in assuming this is the one he’s talking about. I’m buying from the original innovator and USA based manufacturer because I hate the fact that the came in and undercut him on his own creation and his looks better too. Buy American.

That is one of the main reasons I won't sell on eBay. There are ways to see how many of each product you sell, and I wouldn't be surprised if that information is available or made available to other sellers. On top of that eBay does very little to protect sellers from IP theft. I reported some sellers once who were selling knockoff parts with brand name logos. Clearly copies, and they never contacted me back, or removed the products.
 
Novak Conversions Jeep Wrangler TJ radiator