Ask The Experts You ask the tough questions

Thread Tools Search this Thread
Old 07-27-2008, 07:55 PM   #1 (permalink)
Seasoned Member
Captainneeda's Avatar
Join Date: Dec 2006

AGD Flatline Rebuild Guide (56k beware)

SEE REPOST ON PAGE 3 for photos or this zip download with a PDF.


Ok, folks, if you are like me and enjoy running regs that have a ridiculously high out put range AND a fast recharge rate, you are in luck. Here is a disassembly and reassembly guide that is right up your alley!

The Flatline regulator is a classic reg from Airgun Designs that could make any modern regulator blush... Basically, it combines a stratospherically high out-put with a disgustingly fast recharge rate. And the best part is, they are very cheap and easy to find these days! So, for about 7 bucks in o-rings and about an hour of your time, you can have yourself a really nice adjustable reg.

One side note: This guide is for a 3000 psi Flatline. There are 4500 psi Flatlines are out there, but sadly they not as good (as the 3000 psi version) in my humble opinion. The 4500 psi Flatlines need to be rebuilt quite often and suffer from some odd problems.

Oh, and just for clarification, this reg was sitting in some basement for a decade, this is essentially documenting my rescue effort. But... Onto the guide:

1) Clear a space. Do yourself a favor, clear a large space on a flat table. Vacuum the floor, and made sure it is clean. This makes finding a lost part very easy later.

2) Assemble your tools + parts: You WILL need the following tools...

* 7/32 Allen wrench
* 1/8 Allen wrench
* .050 Allen wrench (the tiny one)
* 7/16 wrench
* Dental pick or probe
* Teflon tape or Loctite thread locker
* AGD Flatline rebuild kit
* Q - Tips
* Paper towels
* Bin for parts
* Gold Cup (BE VERY CAREFUL USING THIS, I will explain later)

Attachment 60308

Item(s) that would be handy to have...

* C-clip ring tool
* Razor knife
* Tom Kaye

Attachment 60309

3) Let's Begin: OK, now that you have all of your tools and a clean space to work, let us begin the disassembly. Take your tank + reg and separate them. PLEASE ENSURE THAT THE TANK IS EMPTY!

Attachment 60310

Attachment 60311 (See how the tank is empty :-p)

Attachment 60312

Now, separate the front pressure regulator. It should just come off with a twist.

Attachment 60313

Take the pressure regulator and set it aside in your bin for now. Now, see that is not such a bad start!

4) Disassembling the On/Off: Grab your .050 Allen wrench and remove the On/Off knob screw.

Attachment 60314

Pop the On/Off... off (haha)

Attachment 60315

Examine what you have so far...

Attachment 60316

Now, with your finger and with a tool, push down on the On/Off until it comes out the other side.

Attachment 60317

Attachment 60318

Keep Pushing until you can remove it with your fingers.

Attachment 60319

And put it into your parts bin...

Attachment 60320

Now, with your pick, remove the On/Off spacer.

Attachment 60321

Attachment 60322

You may or may not be able to see it inside of the On/Off port. If you can't... Give the reg a love tap on your hand (A La, bang in on your palm). It should work it self out. But, if you still cannot get it out... Do not be worried. It will come out at some point further along in the disassembly, just be ready if it falls out and rolls away.

5) Disassembling the tank portion: Turn the reg over and examine the portion that screws into the tank:

Attachment 60323

Remove the C-clip by using a C-clip tool or being VERY carful and using for dental tools...

Attachment 60324

Once the c-clip is loose, remove it.

Attachment 60325

Pull out the spacer and reg spring:

Attachment 60326
Attachment 60327

And inspect what you have pulled out for that area thus far...

Attachment 60328
Next take a look down the reg and look for the on/ off valve.

Attachment 60329 (sorry bad pic)

Using your dental tool again, push down on that valve and give the reg a few whacks against your palm to remove the it.

Attachment 60321

Attachment 60330

Attachment 60331

Sweet! We are now cooking with gas! Take one last look down the reg, if you see the ball bearing, you are in good shape!

Attachment 60332

6) The pressure regulator: Set all of those parts you were just working with aside and grab the pressure regulator from earlier. And pop that tiny o ring on the top off.

Attachment 60333

Next back out the pressure adjustment all the way (just like on a mag).

Attachment 60334

Haha, if you have been through a mag before, this should look familiar. Note: Be careful with the spring pack in there. It is packed with grease that NEEDS to stay on there!

Attachment 60335

Now look down the pressure regulator and using your 7/32 allen, back the piston out of there.

Attachment 60336

Attachment 60337

And, now you have a disassembled reg!

Attachment 60338

7) Re o-ringing the Pressure Regulator: Get that main o ring off of the body and slap the new one on...

Attachment 60339

Redo the o ring on the piston.

Attachment 60340

Push the piton back into place using your dental tool or your wrench.

Attachment 60341
Pop the new tiny o ring onto the top. Should be the second smallest o ring in the pack.

Attachment 60342

Put the adjustment and spring pack back in...

Attachment 60343
And look, we are nearly there!

Attachment 60344

8) Redoing the back portion: Slap a new o ring onto the on/off valve.

Attachment 60345

Reassemble the rear tank portion.

Attachment 60346

SIDE NOTE: For some reason, the c-clip in my kit DOES NOT FIT!!!! BE WARNED. The clip that came out of my reg is on the left, the one from the kit is on the right. I a going to call AGD about this tomorrow morning!

Attachment 60347

Push it all back in EXEPCT the spacer and c-clip. Put the valve, spring, and spacer in, in that order. Then seat the whole thing with your wrench.

Attachment 60348

Next push in the c-clip and seat it with your c-clip tool or a dental tool

Attachment 60349

Next, inspect the on/off tube, do you see the top of the valve?

Attachment 60350
Next, using your dental tool, add back the spacer. MAKE SURE THE CONCAVITY OF THE SPACER MATCHES THE CONCAVITY OF THE ON/OFF WALL!

Attachment 60351

Attachment 60352

Then, using your dental tool, push it down so that the spacer is flush with the rest of the surface. If it does not go in flush, reassemble the on-off switch FIRST.

Attachment 60353
Next, get those old o rings off of the On/Off, and put the new ones on...

Attachment 60354

Attachment 60355

Attachment 60356

Then push the on/off back into the reg, ENSURING that the cam in the center of the on/off in vertical, or in the 'up and down' position!

Attachment 60357

Attachment 60358

Next, put the on/off knob back on top and screw in the on/off retaining screw.

Attachment 60359
Lastly,put a new tank o ring on. (Sorry I do not have a picture for this on). But, it should be very easy. Basically, it is only o ring in the previous picture (Bottom left hand corner)

Now, Screw the Pressure Regulator back into the Rear assembly. Make sure to torque down to at lease 25 pounds...

Attachment 60360

9) Fill Nipple and Check Valve... Using your 7/16 wrench, Take the fill nipple off.

Attachment 60361

Take out the check valve.

Attachment 60362

By any means necessary (knife in my case), remove the old o ring. Then slap the new one in. It should be the smallest o ring in the pack.

Attachment 60363

Then, use some thread locker or teflon tape and screw the fill nipple and valve back in...

Attachment 60361
And one last picture of all the tools I used...

Attachment 60364

IMPORTANT NOTE: I used a small amount of of gold cup to clean crap out of my reg while I was disassembling it. I would ADVISE AGAINST using it unless you know what you are doing!!!!!!

For instance, if you accidentally used gold cup oil ANYWHERE near your fill nipple, you run the risk of turning your reg and bottle into a diesel engine....

Think of it this way... OIL + HEAT + COMPRESSION + 0^2 = MASSIVE BOOM!

And no... the danger in not just localized to your fill nipple... if you don't know where it is safe to use. DO NOT USE IT! Basically is you are forced to use it, only use it FORWARD of the on/off, and make sure to wipe up ANY excess...

And you have a new reg! Hope you guys enjoyed the read!


Last edited by Captainneeda; 03-17-2019 at 07:39 PM.
Captainneeda is offline   Reply With Quote
Old 07-27-2008, 08:28 PM   #2 (permalink)
Morfesto's Avatar
Join Date: Nov 2007
Location: Ottawa, On.
Send a message via ICQ to Morfesto Send a message via AIM to Morfesto Send a message via Yahoo to Morfesto

Wow very nice and thorough.

Maybe this should be moved to the ADG section and stickied!
Spyder Aggressor -- Palmer stab - milled for timmy bolt
Automag -- ULE body - Q-loader - Logic 90° frame
Pump Autococker -- Palmer Fatty stab - WWA pump kit
PGP -- Kframe - Quick Changer - CooperT Bolt
KP2 -- Performance tune and side tube re-addition by Dan Sergison
PMI-1 -- Mint
Morfesto is offline   Reply With Quote
Old 07-28-2008, 08:14 AM   #3 (permalink)
Back on the ice
Zoo's Avatar
Join Date: Aug 2007
Location: Blue Jackets' HQ

Excellent job! And those pics are great!
__________________ & Facebook

Trying to register on PM 'Beemer' here to get you set up.
Zoo is offline   Reply With Quote
Old 07-29-2008, 08:05 AM   #4 (permalink)
Seasoned Member
Captainneeda's Avatar
Join Date: Dec 2006

Originally Posted by Morfesto View Post

Maybe this should be moved to the ADG section and stickied!
I was thinking that, but I am not sure. Is that section just for markers?
Captainneeda is offline   Reply With Quote
Old 07-30-2008, 04:42 PM   #5 (permalink)
Seasoned Member
Captainneeda's Avatar
Join Date: Dec 2006

UPDATE: So, I called AGD about the c clip Issue... you know, this one...

Anyway, it appears that the larger c clip is for a 4500 flatline, NOT a 3000. It was just an 'oops' on the part of AGD. They confirmed that any further rebuild kits for the 3000 psi system WILL include the smaller c clip!

Captainneeda is offline   Reply With Quote
Old 07-30-2008, 05:33 PM   #6 (permalink)
Brass Monkey Customs
Stuffy's Avatar
Join Date: Sep 2007
Location: MD for now
Send a message via AIM to Stuffy

Fan of EMR
Brass and Wood Fan
Wow, very detailed and informative guide. Hopefully this will get sticked.
Originally Posted by hey_yeo View Post
Crossing the street in a third world country is my favorite extreme sport.

/ Feedback / Portfolio / Channel / A Review / WTB: Green JT IZE-Flex Mask/Parts! /
Stuffy is offline   Reply With Quote
Old 05-26-2009, 11:12 PM   #7 (permalink)
Rec Poster
Join Date: Mar 2008

very good

2 small points to consider though:
the on/off knob and switch should be installed first...then the valve and spring.
The regulator should be torqued on to 25 ft lbs. Other that that a fine job.
tunaman is offline   Reply With Quote
Old 05-27-2009, 12:32 AM   #8 (permalink)
Wookie D*ck
russc's Avatar
Join Date: Apr 2006
Location: Vancouver, BC

so...what do you use the flatline 13ci tank on?
russc is offline   Reply With Quote
Old 08-24-2009, 12:06 AM   #9 (permalink)
Seasoned Member
Captainneeda's Avatar
Join Date: Dec 2006

a phantom, lol

Oh... and this:
Originally Posted by tunaman View Post
2 small points to consider though:
the on/off knob and switch should be installed first...then the valve and spring.
The regulator should be torqued on to 25 ft lbs. Other that that a fine job.
Agreed, 100%! You do not want the front of your reg coming off mid game.
AGD Flatline 3000 Rebuild Guide (It Rocks)

NGS CV1 'slapstick' 12-gram changer review (It Rocks)

My Feedback (It Rocks)

AO Feedback (It Rocks)
Captainneeda is offline   Reply With Quote
Old 08-24-2009, 12:39 AM   #10 (permalink)
Post Whore
Chemical-X's Avatar
Join Date: Apr 2006
Location: Fort Wayne, IN

Impressive breakdown and info sheet.

I wish I still had my flatline now.

Keep up the good work.
Of course if you are local there is always delivery by trebuchet. However, either method of delivery requires wrapping in a plastic bag to prevent leakage of urine.<from pickle>
Chemical-X is offline   Reply With Quote
Reply » Paintball » Ask The Experts

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Forum Jump

All times are GMT -4. The time now is 05:01 AM.

Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2019, vBulletin Solutions, Inc.
Search Engine Optimization by vBSEO
© MCB Network LLC