Nerf Vortex Vigilon Mod

This instructable brings you in detail through the complete Vigilon mod, including removal of safeties, increasing torsion spring tension, WITHOUT needing the complete removal of breech/chamber assembly, and INCLUDES the reassembly (!), something which seems to be missing in almost all guides (which usually just says "do everything so far, just in reverse"). This mod takes about 30 minutes.

Please note that if you only wish to increase the torsion spring tension (READ: LONGER RANGE), you can skip the safeties removal steps  starting at step 5, and start at step 8 instead, "Locking back the main spring lever".

Please note that modifying your Nerf Vigilon may decrease the overall lifespan of the product, and make the toy a little more _dangerous_ to use. Use discretion especially if young children are using the weapons, and always try to play with safety goggles on.

Step 1: Tools

To do this mod, you need:

1. 2" length of 3mm diameter metal rod (brass is pictured)
2. philips head screw driver
3. Optional, but useful, a pair of needle-nose pliers
4. a pair of 'cut-flat' snips

Step 2: Disassembly (Part 1 of 3)

BEFORE ANYTHING ELSE, clear your weapon: Check that the chamber is empty, and the trigger is squeezed off if possible.

Start by removing 15 screws on the left side of the Vigilon. 14 of these screws are about 11.5mm in length. 1 is only 9.5mm in length, and in the attached diagram is marked with an 'S' for your reference.

Step 3: Disassembly (Part 2 of 3)

There is one more screw under the slide assembly. Take note also of the alignment of the gunsight for easy re-assembly after the mod.

Step 4: Disassembly (Part 3 of 3)

Release the magazine catch before attempting to pull the case apart. You will see the magazine spring and the Nerf disc plunger immediately. Remove them all and set aside.

Step 5: Safeties Removal (Group 1 of 3)

The first set of safeties manage the locking of the weapon slide when no rounds are present, or when the magazine cover is open. If you look up at the underside of the chamber, you can see two levers sticking into the magazine volume.

To remove these safeties:

1. Push the two levers inwards with your left hand, and use your right hand to slide back the charging rod
2. Once the charging rod is slid back, you will see the safety levers
3. Just use your needle-nose pliers (or just your fingers) to pull these levels out by rotating them. Remember to remove the springs completely (instead of letting them fall into the weapon, rattling around and potentially causing jams in the future)

Step 6: Safeties Removal (Group 2 of 3)

The second group of safeties prevent the trigger from being depressed when a chamber jam is present. To remove these, identify two cylindrical plugs just under the chamber of the weapon, in front of the trigger assembly. Using your finger, press down these plugs and snip off the cylindrical plugs.

Step 7: Safeties Removal (Group 3 of 3)

The third safety prevents the weapon slide from being cocked back when there are no more rounds in the magazine. You can just snip off about half of the catch pictured in the attached image.

Step 8: Locking Back the Main Spring Lever

Pulling back the charging rod SLOWLY, you will notice that it clicks as you slide back, and at one of the clicks, the charging rod actually locks with the main spring lever BEHIND a hole in the white spring assembly.

Lock back the main spring lever by inserting the 3mm rod into the hole, in front of the lever, past the other side of the main spring assembly. I believe this hole is also used during the factory assembly process for this same purpose.

Step 9: Removal of Front Cover

Looking at the front (top) of the weapon and you will see a screw to be removed. This screw goes into a retaining plastic nut. Just in case the nut falls out, orientate yourself on how it is positioned as you unscrew this screw.

On the right side of and behind the main spring assembly, remove two screws. One of them is flanged, for your reference.The one without the flange locks down the main spring assembly, and removal of the second flanged one gives you some allowance as you remove the front cover.

Work the front cover off slowly. Don't force it! If it is stuck, there is probably a small catch that can be nudged away from. You will, however, experience some difficulty with a catch on the lower left. Gently push the BOTTOM of the main spring assembly towards you, and the catch on the front cover will clear the obstruction eventually.

Step 10: Removal of Main Spring Assembly

To remove the main spring assembly, first locate and remove two screws locking down a retainer plate.

Once the retainer plate is removed, slide the main spring assembly forward until is seems stuck, then rotate the whole assemble counter clockwise about 30 degrees before sliding off the assembly completely.

You may need to push the whole assembly against the main spring lever (now you know why we half-charged the weapon and put in that metal rod) firmly to slide the assembly forward.

Step 11: Dis-arming the Main Torsion Spring

Next let's look at the main spring assembly. We need to remove the locking pin and unload the main spring safely.

Start by identifying the parts. Look for a translucent rubber bumper with a small spring. It is held in place with a pin.

Carefully pull apart the assembly at the arrowed points (top). The assembly halves will bend, and release one end of the bumper pin locking in the rubber bumper. The bumper spring will fall out. Only pull apart the halves just enough to clear this pin on ONE side

Once the locking pin is cleared on ONE side, transfer your grip to the main spring lever instead. Push it back very slightly (increase tension) to release OUR improvised locking pin. You can now rotate the left half of the main spring assembly clockwise, out of the way.

Further pressure on the main spring lever liberates the bumper, which you can now remove, and with the bumper out of the way, slowly allow the spring to rotate counterclockwise, releasing the tension in the main spring.

You can now see the spring pre-tensioner. Success!!!!

Step 12: Adjusting the Main Spring Tension

As you can see, there are 3 lugs for 3 different levels of pre-tension. While most people are looking to increase the tension (to the leftmost lug), soem may even be looking at moving the pre-tension position to the right (less range, less wear and tear on the weapon), which may actually be necessary if you have small children playing with this Vigilon.

This step is easy. Just unscrew the retaining screw (with the flange), move the spring end, and re-secure.

Step 13: Reassembly - Main Spring Assembly (Part 1 of 2)

Pre-load the main spring lever with one hand (left half of assembly in your palm, forefinger pushing back the spring), and insert the bumper. You should see a circular impression on the bumper left behind by the bumper spring. This impression should be on the opposite side of the main spring lever.

Rotate the left half back to secure the bumper locking spring. You may need to push and nudge a little on the bumper to get it to fit okay.

Once the two halves are aligned, you will see the bumper resting against the bumper spring retaining stud. Pull back the main spring, insert our improvised rod again, and now you have space and time to push back the bumper spring.

Step 14: Reassembly - Main Spring Assembly (Part 2 of 2)

Now maneuverer the main spring assembly back to its place in the weapon. Yes, pretty much the same way, in reverse :-)

Be aware that our main spring lock pin may obstruct you from below, unseen.

Once the main spring assembly is back in place, replace the retainer plate (2 screws).

Replace the front cover, again pushing the main spring assembly up to accommodate that pesky catch on the bottom left, and replace the front cover screw.

Replace the two screws securing the main spring assembly and the breech/chamber assembly.

Once you have done this, cock the weapon and squeeze off the trigger to verify if everything is in place so far.

Step 15: Reassembly

Now you are ready to replace the main casing!

1. Ensure that your attachment rail lug is in place
2. replace the magazine plunger and magazine spring: there's a little catch for the spring (see attached pic)
3. As you replace the casing, push down the plunger slightly and ensure that the magazine release lever is in the horizontal position.

Step 16: Slide and Lots of Screws

Once the main casing is back, remember to first replace the screw at the end (the one that was below the slide), and its time to replace the slide and all the other screws.

I have the screws location diagram here again for your reference, especially where that ONE short screw is supposed to go.

The final pic here shows the completed mod and parts removed from the weapon (less one safety spring).