Deadlywind Foehn V2.5 and Negative "Bolt Out Back" (BOB™) Instructions
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The "Bolt Out Back" (BOB™) feature has been implemented in all of our Foehn 2.x+ body kits, but starting with the Foehn v2.5 and Negative body, we changed the tail plug design to be more robust, simpler, and more compatible with aftermarket firecans.
With the BOB™ concept, we replace the Ion's "Air donut", but keep and utilize the already existing threaded firecan of the Ion. Once installed, the BOB™ system only takes a few seconds to remove the bolt.

The Foehn and Negative body kit includes the body shell, a metal low profile air fitting to replace the stock plastic Ion 90* rear banjo fitting, and BOB™ tail plug to replace the stock Ion "swivel" air donut.

Initial installation of the Foehn V2.5 and Negative 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 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. Unscrew them completely and remove the O-ring from the back end of the breach (see picture). It is not needed and will only make it harder to remove the bolt later. Screw the firecan and breach back together.

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 stock Ion black aluminum air donut off the tail.


5) Locate the included BOB™ tail plug.
6) Ensure there are two #024 O-rings on the BOB™ tail plug. They should be slightly loose in the grooves (If they are not loose in the grooves, they are too small-- replace them with the correct #024 size). Apply some Ion/shocker lube to them.
7) Remove the plastic 90* banjo fitting from the short hose coming from the back of the Ion solenoid. Connect this short hose onto the metal fitting on the bottom of the new body. The metal fitting should be facing forward-- if it is not, it can be rotated. Once aligned forward, make sure the fitting is snug to the body-- it does not need to be super tight. Re-connect the ACE wire and install the front plastic banjo fitting (or QEV).

8) Re-assemble everything with the new body. Leave the BOB™ tail plug off for now. During assembly, Do not install the rear frame screw yet and leave the middle frame screw loose. Tighten the front lip frame screw.
9) Install the tail plug into the back with the threaded hole pointing downward, so that it will align with the rear frame hole.

10) When sliding the tail plug into the back of the body, make sure that the large O-rings around the tail plug do not catch on the body edge and get cut. Push it in all the way and rotate it slightly as you insert the rear frame screw until you feel the rear frame screw "catch" into the tail plug threaded hole.


(This is bad for the O-rings. Help them in with your fingers if this happens.)

11) Tighten the rear and middle frame screws.
11a) Done.

 

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) Using your fingers, pull the tail plug out the back.

4) Using your fingers or the Ion spanner wrench, grab the tail of the firecan and unscrew it out the back.

5) Remove the firecan and bolt out the back.


To re-install the bolt (reverse of the removal process):
1) Install the bolt into the Firecan and/or Breach.
2) With the middle frame screw loose, insert the firecan in from the back of the body and screw it into the breach. Snug it with your fingers or the spanner wrench included with your Ion (or any other wrench).
3) Follow steps #9-11a above.


WARNING!! The middle triggerframe screw (the one inside the trigger guard) MUST be loose when removing or installing the firecan. 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. Some people leave this screw out all the time and use the front "lip" screw and tail screw only. This might work for you.


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 tail plug 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.
iv. Check the short air hose connecting the solenoid to the metal fitting under the body.