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The
"bolt out back" (BOB™) feature is implemented in
all of our Foehn 2.x+ body kits.
We replace the "Air donut", but keep and utilize
the already existing threaded bolt tube of the Ion. Unfortunately
this upgrade is not backwards compatible with the Foehn
V1.0 bodies.
The
BOB system will require a little bit of "setup"
to install, but once it is in, it will only take 5 seconds
to remove the bolt, and about 20 seconds to install it using
only a couple of Allen wrenches and removing only 1 screw.
The
Foehn body kit includes the body shell with, an air fitting
to replace the stock Ion 90* rear banjo bolt, a new black
Delrin "air donut" and an anodized aluminum Access
Plug. The black Delrin replaces the Ion's aluminum air donut,
and the new Access Plug replaces the original Deadlywind
back plug.
The
Access Plug has a Torx socket milled inside it which will
"loosely" engage the Ion bolt chamber's hex shaped
tail. The Access Plug has a 3/16" Allen wrench socket
out the back of it and 5x possible threaded locations around
the perimeter. More on this later.
Initial installation of the Foehn V2.x body kit:
1)
Completely remove the old, junky plastic body shell (refer
to the Ion owner's manual for disassembly instructions),
and throw it as far as possible. :
2) At this point, the rearward Ion bolt chamber and front
Breach should be removed but still screwed together. Unscrew
them slightly with your hands- it should not take too much
force. This is the joint that will allow the bolt assembly
to be unscrewed and removed out the back. Screw them back
together lightly for now.
3) Remove the metal clip off the tail of the Ion (it may
scratch some of the hex area of the tail- this will not
hurt a thing)
4) Remove the black aluminum air donut off the tail.
5) Slide the new black Delrin air donut on in place of the
stock black aluminum one.
6) Ensure there are two #24 O-rings on the black Delrin
air donut, and apply some Ion/shocker lube to them.
7) Make a mark (light scratch) the bottom of the bolt chamber
near the back. This will help in alignment in the future.
8) Slip the black aluminum Access Plug onto the tail end
of the bolt chamber. It should slide up against the black
Delrin air donut. Notice how it can rotate slightly in each
direction. This is intentional. There should be about 22
degrees of rotational freedom here.
9) Notice the 5x threaded holes around the perimeter of
the black aluminum Access Plug. You will only be using one
of these. This is what the back triggerframe screw will
be bolting into.
10) There are 6 positions this Access Plug can slip onto
the hex tail of the Ion bolt chamber- pick one that allows
one of the 5 threaded holes to be pointing directly down-it
should be aligned with the scratch/mark from step #7 above.
11) Make a Mark on the black Access Plug near this one hole-
It will most likely be the one you will use.
12) Unscrew the rearward Ion bolt chamber and front Breach
completely now, and set them aside for now.
13) Moving to the Circuit/Solenoid/Air fittings, remove
the back air banjo bolt. (says "5/32" on the grey
ring).
14) NEW BOB™ AIR FITTING update: Please
see the "initial install step-through" above for
details!!
14a)
(older style)The 90* air fitting hanging off the bottom
of the Foehn body will be taking the place of the original
air banjo bolt that was there. This might require some working
to get the air tube to slip onto the new 90* fitting- It
will be tight. Heating the tube slightly should help it
stretch on. The new 90* air fitting on the bottom of the
Foehn body is secured and sealed with RED Loctite. If for
any reason it breaks loose (takes quite a bit!), unscrew
it, clean the threads, re-apply RED Loctite and screw it
back in so that it does not protrude through into the inside
of the body. It should be pointing directly forward. Let
the Loctite cure for about 1-2 hrs.
15)
Grab the feed breach section (front half what was unscrewed
in step #12 above) (install the ACE board), and slide it
in from the front of the Foehn body.
16) Re-assemble the board/solenoid/air fitting back into
the triggerframe, re-connect the ACE cable, and place the
Foehn body back on top of the trigger frame making sure
not to pinch any air lines or the ACE cable.
17) Install the front bolt (under the barrel) but do not
tighten yet! Install the middle bolt (in the trigger guard),
but do not tighten yet!
18) Slide the rear half of the bolt chamber in from the
back of the body. Make sure the marks/scratches on the bolt
chamber and the Access Plug can align up. Use a 3/16"
Allen wrench in the tail of the Access Plug to "screw"
everything in as you slide it in. It will catch and engage
the main chamber threads and eventually tighten up.
19) Install the back triggerframe screw and lightly keep
pressure on it pushing it in while you perform step #20
below:
20) While you still have the 3/16" Allen wrench in
the tail, you will use the 22 degrees of rotational freedom
in the Access Plug now to back it off the other direction
and find the point at which the back triggerframe screw
will find that 1 of 5 threaded hole- when it does, simply
thread it in and tighten it down. If it does not "find"
the right hole, you might need to remove the Access Plug,
rotate it, and try again until the screw finds one of the
5x holes. There is always ONE and ONLY ONE hole that will
work, but you have to find it in one of the right 1 of 6
rotational positions.
21) Tighten the front frame screw (under the barrel), and
the finally, tighten the middle frame screw.
To remove the bolt in the future:
1) Remove the back triggerframe screw completely
2) Loosen the middle triggerframe screw, removal is not
required.
3) Use a 3/16" Allen wrench and unscrew the Access
Plug out the back-it will unscrew the rear bolt chamber
with it. Once it is fully un-threaded, remove the Access
Plug with your fingers, followed by the bolt chamber by
grabbing the tail and pulling it out.
4) If the bolt chamber is hard to rotate or remove out the
back, try the following:
a. Make sure the back bolt is completely removed.
b. Make sure the middle bolt is loose!
c. Remove the barrel and push the bolt out the back from
the front, using either your finger or a squeegee.
To
install the bolt in the future:
1) Making use of the marks on the bottom of the components
(bolt chamber and Access Plug) make installation much faster.
They allow you to get the right 1 in 6 rotational alignment
every time without having to guess every time.
2) Simply follow steps #18 - #21 above.
WARNING!! You MUST fully remove the
back triggerframe screw, and loosen the "middle"
triggerframe screw (the one inside the trigger guard). Removal
is not required of this screw, but it must not be tight.
This is due to the way the BOB system engages the threaded
portion of the bolt chamber, and the way the Ion bolt chamber
is designed.
Problems:
- There is air leaking out the back of the gun body when
I gas it up:
i. Try gassing it up quickly at first. The o-rings on the
black Delrin Donut need to fly out to seat in.
ii. Check the inside rear of the body for large scratches
and/or debris.
iii. Check the 90* air fitting underneath the body to make
sure it is not loose.
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