Sunshine Garage Mk IV Roadster
The construction of a Factory Five Mk IV Roadster
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Build Overview
Build Blog
Construction steps
Build Checklist
Body buck construction
Front suspension
Front disc brakes
3-link
Rear brakes
Steering rack
Fuel supply
Pedal box
Brake lines
Aluminum
Emergency brake
Footbox fresh air vents
Instrument panel
Glovebox fabrication
Cooling systems
Engine Installation
Hydraulic clutch lines
Photo Album Directory
Fasteners photo album
Body buck album
Front suspension album
Front brakes
3-link
Rear brakes
Steering rack and column
Pedal box
Fuel Tank
Brake lines
Aluminum
e-brake
Footbox vents
Electrical system
Instrument panel
Glove box
Cooling system
Engine installation
Supplemental Technical Data
AN to SAE Conversion
Brake Balance v. Deceleration
Brake System Calculations
Fasteners and fittings
Fluid Line Clamp Spacing
Links to technical information:
Tap and Clearance Drill Sizes
Tools
Road and Track (2013)
Torque specs: Factory Five
Torque specs: SAE Grade 8
Aluminum
DS footbox on chassis
Disassembling the DS footbox Al
De-burring rivet holes using a countersink
Cherry-Q structural rivets
Comparison with Factory Five supplied rivets
Bedliner
Bedliner on test panel
GE Silicone II for bonding panels
Firewall rivet hole spacing
Access panel on DS footbox for pedal box top
DS footbox
DS aluminum mating
DS footbox
DS footbox
DS footbox after fitting
DS footbox floor held in place with Cleckos
DS footbox floor riveted in
The underside of the floor is coated with Rustoleum bedliner
Rear brake lines under the DS footbox floor
Completed DS footbox Al
Using the rivet spacing tool
Cockpit side of passenger footbox
Cockpit aluminum
Frontal view of footbox Al
Temporarily fitting the cockpit floor Al
Transmission tunnel end ready for riveting
Aircraft Tool Supply hydraulic riveter
PS footbox
PS footbox detail
PS footbox gap
Fitting cockpit Al
Hydraulic riveter
PS floor (roadside) marked for rivet holes
PS cockpit floor rivet holes
Passenger footbox detail
PS chassis floor with rivet holes
De-burring Al panels
Al gap without the floor pan modification
Under-door Al with flattened cockpit floor
Material to be removed so the floor panel can lie flat
Welding materials keeping the floor panel from lying flat
DS footbox access hole with rivets
Installing rivets
DS access panel in place
Master cutoff switch in place
Firewall riveted in place
Firewall strengthening panel
Cockpit floor door sills
‘H’ piece at tunnel top near dash
Rear tunnel piece
Cockpit rear side pieces with bedliner
PS footbox hole patch
DS footbox end in paint booth
PS footbox completed
Passenger side footbox with air vent plate
Interior of passenger side footbox
Underside of passenger side cockpit floor w/ undercoat
PS cockpit floor
PS door sill
Rear transmission tunnel housing
Detail of rear cockpit aluminum
PS aluminum installed
Cockpit aluminum
Fuel tank access hole in trunk Al, w/ rivets for cover
Fuel tank access panels in place
View of rear cockpit Al
Trunk Al
Upper trunk Al
Lower trunk Al with marking for riveting
Upper trunk Al drilled
Upper trunk Al sprayed with undercoat
Lower trunk Al sprayed with undercoating
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