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
Footbox vents
Flue damper valve (Go2Marine p/n 16-011)
3 in. cutout in PS footbox top
Reinforcing plate made from 0.04” Al
Air duct mounting plate (SPE-8148) attached to reinforcing plate
Air duct mounting plate and coupler (SPE-8776)
Air intake tube (SPE-9480) attached to air duct mounting plate
Air intake tube
Rivnuts set for mounting Atwood blower
Atwood 3000 blower in place
Atwood 3000 blower in place
Atwood blowers mounted on both sides of chassis
DS footbox front with 3 in. hole for mounting damper valve
ABS cleanout adaptor
DS reinforcing plate
DS reinforcing plate in place
ABS cleanout adaptor cut to make retaining ring (right)
Flue damper held in place with ABS retaining ring
Side view of flue damper and retaining ring
Flue damper, reinforcing piece in DS footbox front panel
Inside footbox view of flue damper and retaining ring
PS footbox vent system
DS footbox vent system
PS vent parts
DS vent parts
Damper valve connecting piece: damper closed
Damper valve connecting piece: valve open
F-panel cutout for hose
DS splash guard cutout template and initial cut
DS splash guard rough cut
DS hole fitting
Interior look at DS splash guard cut
Finished cut with splashguard in place
IMG_4133
Hose in place
Top view of pass through
Side view of pass through
Rear view of pass through
Oblique view of pass through
PS splash guard pass through
View from front of ‘elephant ear’ pass throughs
PS view
Routing of electrical conduit
Cutout for electrical conduit
Grommit for conduit
Electrical conduit pass-through
Aft view of conduit pass through
Conduit pass through
Side DS view of vent hose and conduit pass-through
Electrical conduit to headlights
Atwood 3000 connected to power and ground wires
Using cable insertion tool for blower wires
Using cable insertion tool for blower power wires
Wires inserted in conduit
Wires inserted in conduit
Temporary terminus of blower power wires
Completed pass-throughs
Completed pass-throughs
Routing of blower power on PS
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