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
Front suspension album
F5 Lower Control Arms
Lower Control Arm Fasteners
Koni Series 30 Shock info
Staging LCA and UCA parts
Breeze bushings
Koni shock firmness adjustment button
Front shock mounting hardware
Shock assembly components
‘Hat’ slipped over shock arm
‘Hat’ in place
Completed shocks (note zip tie)
Correct UCA ball joint plate orientation
PS LCA gap
Comparison of F5 and McMaster-Carr washers
Washer comparison
Washer in place: DS, rear
Washer in place: PS, rear
LCA prior to final bolt torquing
Grease gun on Zerk fitting
Torquing the LCA bolt (110 ft. lbs)
Torqued PS, rear LCA
LCA, UCA in place
Lower front shock mount spacer gap
Driver side view
Passenger side view
Passenger side view
Driver side view
Torquing hub
Hub in place with dust cap
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