Yep, it's been over two years since you've seen our Juggy project in these pages. It's all Cappa's fault, that's all there is to it. Since its last appearance ("Juggy, Part VI," April '04), Juggy has been in the cooler waiting patiently while other Jeep projects received needed attention. So with summer looming, we decided to show you what we did to keep our swapped-in GM LS1 V-8 and TH400 auto tranny cool in all wheeling conditions.
f you're planning on bending up brake, fuel, and tranny lines, get your hands on one of these small tubing benders (red tool on top of tranny). We found ours at Pep Boys, and it makes clean-looking | 
Earl's has more fittings and hoses than Courtney Love has addictions. The Super Stock ends and hoses are our favorite (stainless braid looks tacky). The Super Stock ends are clean-looking and feature the common 37-degree AN flare. The hose is available in blue or black and is rated to 250psi. It can be used for fuel, oil, and water. We ran Super Stock on our tranny cooler lines, EFI fuel lines, and | 
We wanted to use an easy-to-get and inexpensive radiator that was designed for a V-8. Poison Spyder Customs (the manufacturer of our Bruiser chassis) recommended using a '67-'69 Camaro unit because it's fairly common, fits well behind the skinned TJ grille, has sturdy mounting tabs, and should have no problem cooling a V-8 because that's what the Camaro came with. We went to radiatorbarn.com and found this three-core |
All the dimensions of the radiator were right there online, so we could make sure it was going to fit beforehand. We added some 1-inch tubes and 18-inch-thick strap steel to the chassis and then bolted the radiator home. The radiator mounts double as headlight mounts too. | 
We added a Flex-a-lite Black Magic Xtreme electric puller fan (PN 180) behind the radiator. The Flex-a-lite shroud has threaded bungs that make mounting easy. It comes with a thermostatic control, but we wired ours into the LS1 crate | 
The LS1engine has the coolant inlet and outlet on the passenger side. We built a 112-inch transfer tube that bolts to the radiator mount, then used a Summit Racing universal stainless steel radiator hose (PN SUM-390112) to plumb the connections where there were goofy bends that might kink other hoses. The lower hose is the same part number. The included adapters let you fit the hose up to several |
For the radiator overflow, we added a pair of tabs to the chassis and bolted up a Jaz Products radiator overflow (PN 602-025-06). It's clean, simple, and fits perfectly behind the passenger-side headlight. | 
We wanted a plate-style tranny cooler because they are the most efficient at transferring heat. We ordered the biggest Earl's oil cooler and mounting brackets we could fit (34-row, PN 43406ERL). Lots of sizes are available to fit any application and space. We mounted it under the driver seat and welded 112-inch-wide strap steel to the chassis for mounts. | 
A 10-inch Flex-a-lite fan also bolts to the mounts and is wired to a Painless Performance thermostat switch that kicks the fan on at 180 degrees. We also wired in an override switch to turn the fan off in case we hit deep water. |
Earl's Temp-A-Cure coolers are available with fittings ranging in size from 38 barbs to huge -16 AN fittings. Our -6 fittings are O-ring sealed, so we lubed them up before installation and used two wrenches (one on the cooler and one on the fitting) to keep from damaging the | | |