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SpecificationsLength: 36 inchesWeight: 2lbPlunger load: 18-32lbSpring load maximum: 38lbOptimal Barrel Length: 12 inchesPerformancePlunger rod has th...
Download the cuttings template sheets: plusbow_templates.doc (100kb)Print them on full sheet label paper. If you ran out of color ink (like I did) mak...
Cut out all of the templates from the full sheet. Set aside the labels indicated in the picture because you won't be applying them right away. They ...
Apply the cutting templates to the indicated thicknesses of polycarbonate sheet. You can group them fairly close together to minimize excess, but kee...
Cut the labeling sheets into smaller more manageable sections using a scroll saw or band saw. Wait to cut out all of the small parts until later. Thi...
Using a drill press or power drill follow the color legend you printed or wrote on the labels to drill out all of the holes to the required sizes. Al...
Use a scroll saw or band saw to make all of the external cuts needed to free and shape all of the parts out of the sheet.
Use a scroll saw to make all of the internal cut outs. Start by feeding the blade through the pilot hole you drilled in Step Five then retensioning th...
Now all of your plastic sheet parts are cut out.
Using the side plates that they will eventually screw into as a guide, mark the edges of both sides of the frame pieces as shown.
Using a 7/64" bit in a drillpress or power drill drill to a depth of around 1/2 of an inch. Then tap the holes with a UNC #6-32 tapping bit.
Using a mitre saw with box, table saw, table saw, or circular saw cut a 7/16" length section off of the 1" diameter plastic rod. Using the 1/8" thick...
Using a mitre saw with box, table saw, table saw, or circular saw cut two 11-1/4" length sections and one 12" length section off of the 1/2" diameter ...
Remove the cutting templates and protective film from the plastic sheet parts. The catch plate will need its lower edge beveled and the corners of the...
Deburr the edges of all of the sheets using a hobby knife To quickly remove the burrs simply orient the blade perpendicular against the edges of the s...
Using the 1/8" thickness plunger rod part as a template, mare the front edge of the plunger rod. Using the front piece of the adapter bracket, do the...
Squeeze two Dash 316 O-Rings onto the 7/16" section of 1" diameter plastic rod. Sandwich it inbetween the 1/8" and 1/4" thickness plunger head pieces ...
Assemble the center frame piece and catch plate together as shown using washers and 1" length screws. Attach the 12" length section of 1/2" diameter ...
Install a 1" length spring (one with a load between one and ten pounds) onto the catch plate and the set screw.
Attach the 11-1/4" length sections of 1/2" diamter rod to both the rear frame piece and the butt stock using 3/8" length screws.
Slide the 12" length rod through the 1/2" hole in the rear frame piece and then bolt it to the butt stock using 3/8" length screws.
Attach the side plates to the center and rear frame pieces using 3/8" length screws. Use one of the grip pieces as a template to mark the edges on bo...
Attach the front plates to the side plates using two 1/4" length screws, four 3/8" length screws, and two 1-1/2" standoffs. Wrap and tie a rubber band...
Place the plunger cross where shown inbetween the 1" screws protruding from the front of the center frame piece.
Assuming you order exactly one foot of the 1-3/8" ID polycarbonate tube it should already be at the length you need. If not then use a mitre saw with ...
Mark where shown. Using a 5/32" bit in a drillpress or power drill drill where marked on both sides.
Insert the hex bushing adapter into the end of the plunger tube and mark it as shown as well. You don't want to drill the holes in the hex bushing to...
Wrap the hex bushing in 3 or 4 layers of electrical tape then use a hobby knife or ice pick to poke through the drill holes in its sides. Push it int...
Remove the new plunger tube assembly from the rest of the gun as shown.
Clean out the inside of the plunger tube then spray a generous amount of silicone lubricant into it. ONLY USE SILICONE LUBRICANT WITH PLASTICS. It's ...
While depressing the catch plate by hand, slide the plunger rod through the plunger cross, center frame piece, catch plate, and rear frame piece. Rea...
Use one of the grip pieces as a template for marking the 3/4" thickness polyethylene foam sheet. How much padding extends away from the grip is up to ...
Finish marking like so and the foam shouldn't interrupt the trigger. Use a hobby knife or ice pick to stab out the holes. Use a band saw, hobby knife...
Follow the photograph labels for attaching the hardware to one of the grip pieces.
Slide the foam grip core onto the standoffs. Slide the trigger piece onto the 1-1/4" length screws and add another 1/4" length spacer. Install a 3/8" ...
Add a 3/8" spacer to the opposite grip piece. Put a washer and a lock nut on the end of both 1-1/4" length screws, but only tighten them enough for th...
Attach the front of the grip to the side pieces using 3/8" screws as shown. Hook the loose end of the rubber band onto the 3/8" screw you installed on...
Add your preferred barrel, and your gun is now complete. The process has taken anywhere from 6 to 12 hours from start to finish depending on the tools...
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