Novak Conversions Jeep Wrangler TJ radiator

Basket's Build

Weldin' on the downturn. I am sick of how gross flux core welds look, so much splatter. So watch out, here comes some hideous pictures.

The muffler section was kinda mangled from when it got smashed in Moab, so there was a big gap on one side.
1750299855911.jpeg


Since I shortened the flange of the new tube, I had some extra, so I cut that ring in half and used it to make this gap easier to weld.
1750299921885.jpeg



Welded up
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Another one of the hangers split at the toob, probably since I was missing the muffler hanger for a long time
1750300026553.jpeg


Welded that puppy up
1750300043938.jpeg


Also welded on a new hanger behind the muffler. You can hardly tell it isn't factory!!!
1750300095617.jpeg


One more fun surprise, transmission mount ain't looking too hot anymore. I am probably going to replace it while I have the skidplate off.
1750300132862.jpeg
 
Weldin' on the downturn. I am sick of how gross flux core welds look, so much splatter. So watch out, here comes some hideous pictures.

The muffler section was kinda mangled from when it got smashed in Moab, so there was a big gap on one side.
View attachment 624918

Since I shortened the flange of the new tube, I had some extra, so I cut that ring in half and used it to make this gap easier to weld.
View attachment 624919


Welded up
View attachment 624920

Another one of the hangers split at the toob, probably since I was missing the muffler hanger for a long time
View attachment 624921

Welded that puppy up
View attachment 624923

Also welded on a new hanger behind the muffler. You can hardly tell it isn't factory!!!
View attachment 624924

One more fun surprise, transmission mount ain't looking too hot anymore. I am probably going to replace it while I have the skidplate off.
View attachment 624925

Are you running a stock skid still?
 
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Basically the ground needs to be on the positive & the lead is on ground. I forgot to swap mine the last time I was doing Flux-Core.

Oh I see what you mean. I can check when I go out there tomorrow. I've never had gas though so I'd think it's on right?

I think I'm noticing if I don't push the button down hard enough it has a delay in arcing which makes the wire spool out too far then look like crap. I also need to replace my ground clamp tbh it's kinda melted
 
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Weldin' on the downturn. I am sick of how gross flux core welds look, so much splatter. So watch out, here comes some hideous pictures.

The muffler section was kinda mangled from when it got smashed in Moab, so there was a big gap on one side.
View attachment 624918

Since I shortened the flange of the new tube, I had some extra, so I cut that ring in half and used it to make this gap easier to weld.
View attachment 624919


Welded up
View attachment 624920

Another one of the hangers split at the toob, probably since I was missing the muffler hanger for a long time
View attachment 624921

Welded that puppy up
View attachment 624923

Also welded on a new hanger behind the muffler. You can hardly tell it isn't factory!!!
View attachment 624924

One more fun surprise, transmission mount ain't looking too hot anymore. I am probably going to replace it while I have the skidplate off.
View attachment 624925

Are you going with just that straight down output?

If so, I have no experience... but all I've heard is to be cautious of floor reverberations from it - plus a potential build-up of exhaust smells - both especially on trails...

Adding a 45* kink off to the side could help with that. Just sharing.
 
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Reactions: lBasket
Are you going with just that straight down output?

If so, I have no experience... but all I've heard is to be cautious of floor reverberations from it - plus a potential build-up of exhaust smells - both especially on trails...

Adding a 45* kink off to the side could help with that. Just sharing.

Yes, I previously had it going straight back out of the muffler until it melted a JJ, so I'm hoping this will at least be a better situation than that. The exhaust was never really an issue like that but idk if the downturn could make it worse.

If it smokes me out I guess I'll be booger welding another turn on though like you said.

I thought I'd read somewhere a downturn is slightly quieter than straight back too, but even if not I'm thinking it'll be quieter since I closed that crack on the other hanger and will also be replacing a leaky clamp around where the oil pan is. You can see it's letting exhaust out in this pic

IMG_20250618_165728.jpg
 
New clamp
IMG_20250624_173418.jpg

You're supposed to let the goop cure 24h before driving... Whoopsies

New mount
IMG_20250622_195022.jpg


Hopefully no more fried bushings
IMG_20250624_173444.jpg


I hope this bolt touching the muffler doesn't turn into a problem lol
MVIMG_20250624_185203.jpg


It is mildly quieter with the exhaust leaks fixed which is nice, not sure I can tell anything about the new transmission mount but I'll see when I drive it down the highway next. It is quieter without the sway bar inverted, and feels a lot nicer without that JJ being melted. Success!
 
Novak Conversions Jeep Wrangler TJ radiator