FLY 45 SUPPRESSOR MANUAL

The FLY 9 and the FLY 45 share many common design traits but have some differences.
This manual is for the FLY 45. The FLY 9 manual is over here.

SPECIFICATIONS, PERFORMANCE, AND BARREL LIMITS

Please refer to the product information page for general information including barrel length and cartridge restrictions:

  1. FLY 45 SUPPRESSOR SPECS

OPERATOR LEVEL INSTRUCTIONS

GENERAL SAFETY RULES

  1. Do not assemble or disassemble the suppressor while attached to a firearm.
  2. Do not install or remove the suppressor from a firearm while the firearm is loaded.
  3. This is not a comprehensive list of safety rules. Always follow the standard gun safety rules, such as the "NRA Gun Safety Rules" while handling firearms.

PARTS DIAGRAM


SHORT/LONG CONFIGURATION ASSEMBLY/DISASSEMBLY

The FLY can be shot in "SHORT" and "LONG" configurations by omitting or including the MODULE respectively.

To convert from LONG to SHORT: Remove EXIT END from MODULE using a quarter or back of a house key. Next, unscrew MODULE from SUPPRESSOR BODY. Install and tighten EXIT END back onto the end of the SUPPRESSOR BODY. These parts should be "hand tight."

To convert from SHORT to LONG: Remove EXIT END from SUPPRESSOR BODY. Screw the MODULE onto the end of the SUPPRESSOR BODY. Replace EXIT END onto the end of the MODULE (you can use a quarter or back of a house key). These parts should be "hand tight."

REAR CAP AND BOOSTER HOUSING ASSEMBLY/DISASSEMBLY

The FLY 45 ships with an assembled BOOSTER HOUSING ASSEMBLY set up for 0.578-28 pistol threads. The complete BOOSTER HOUSING ASSEMBLY (incl. REAR CAP, BOOSTER SPRING, PISTON, and BASKET) is for use with pistols that use a Browning-style action or otherwise require linear decoupling (ie, most pistols).

For use in fixed-barrel applications, we intend that the complete BOOSTER HOUSING ASSEMBLY be removed to reveal a standard 1.375-24 "HUB" interface. At this point, you may use any HUB compliant mounting system on the FLY 45, provided it does not protrude into the suppressor more than 1.4 inches (ie, "thread end face to first baffle 1.4 inches").

Alternatively, you can leave the BASKET connected to the SUPPRESSOR BODY while removing the PISTON, REAR CAP, and BOOSTER SPRING and use standard 1.125-28 "ALPHA" mounts such as the SilencerCo or KVP Tri-lug adapters.

Tool fitment for REAR CAP: The three-pointed handling interface on the back of the REAR CAP will fit a socket. Specifically, a 6-point 1 1/8" (inch and an eighth) socket will fit the end of the REAR CAP. This may be used if you need to apply more torque than you can by hand on the small handling surfaces of the REAR CAP. Do not over-torque this part; you should not need to use more torque than you can apply by hand holding onto the socket.

Tool fitment for BASKET: The wrench flats on the back of the BASKET fit a 1-5/16 inch wrench or socket. Use similar guidance as for the REAR CAP.

O-RING LOCATIONS AND MAINTENANCE

There are 3 O-rings in FLY 45.

  • One behind the male threads on the EXIT END.
  • One behind the male threads on the MODULE.
  • One on the inside of the REAR CAP where it contacts the shaft of the PISTON.

There is NO O-RING between the REAR CAP and the BASE SUPPRESSOR.

O-RINGS should be checked regularly and replaced if damaged. O-RINGS are available from TBAC or you can use the following part numbers from MCMASTER-CARR: 9464K72 for the REAR CAP; 9464K79 for the MODULE and EXIT END.

USING OTHER ADAPTERS AND PISTONS

As stated above, the rear of the SUPPRESSOR BODY has HUB (1.375x24) threads, while the BASKET accepts ALPHA (1.125x28) thread devices. You may use mounts compatible with either of these depending on the configuration you desire. Note that "self-contained" tri-lug adapters are recommended for compatibility.

The FLY 45 ships with a .578-28 piston. It is compatible with the Rugged/Griffin/SilencerCo/TBAC standard pistons. You should use the TBAC FLY9/FLY45 wave-style BOOSTER SPRING even if you use a different piston (eg, for M13.5x1 LH)

We do not guarantee the function of third-party pistons or rear adapters (ie, adapters that replace the REAR CAP and BOOSTER ASSEMBLY, or the entire BOOSTER HOUSING ASSEMBLY). Be sure the combination you are going to use will not cause problems or baffle strikes. Use of third party adapters and pistons does not invalidate our warranty; however, damage caused by using third party adapters or pistons will not be covered under warranty (it may be fixed at "shop rate.")

INSTALLATION/REMOVAL FROM FIREARM

DO NOT INSTALL OR REMOVE FROM A LOADED FIREARM

Make sure the EXIT END, MODULE (if present), and REAR CAP and BASKET, are all tight and that the PISTON and BOOSTER SPRING are assembled correctly.

For pistols and PCCs, screw the suppressor onto the muzzle threads. Note that 1/2-28 threads on 9mm usually shoulder on a proper barrel shoulder. Other threads such as M13.5x1 LH often shoulder the muzzle on an internal shoulder in the booster.

Periodically make sure the suppressor is still tight on the host. Beware that after shooting the suppressor may be hot.

NOTES ON HOST COMPATIBILITY - SEMI-AUTO PISTOLS

Pistols that use a Browning style recoil system or otherwise need a linear decoupler will use the BOOSTER SPRING in the assembly. Operation of these pistols depends on a balance between: (1) the pistol's recoil spring, (2) the booster spring, and (3) the ammunition strength. We have designed the FLY 9 to allow "most" modern semi-auto pistols that have standard pistol threads to operate without modifications. Keep in mind that spring compatibility may change from LONG vs SHORT configurations and from ammo type to ammo type.

** NOTE ABOUT PISTON COMPATIBILITY WITH MODERN SIG PISTOLS (P365, P320) **
The industry standard is, or has been, that threaded 9mm pistol barrels use 1/2-28 threads and bottom out ("shoulder") on a shoulder behind the threads. This is true for virtually all pistol barrels and virtually all 9mm 1/2-28 booster pistons are designed to work ths way. We have discovered that factory SIG threaded barrels for the P320 and P365 families, and possibly others, are not set up this way. In contrast, they are set up to be indexed on the muzzle, which makes them not compatible with most 1/2-28 9mm pistons on the market.

Our original, or "A" version, 1/2-28 piston is designed to work with muzzle threads that have a thread length of approx 0.40-0.45" and a shoulder behind those threads of at least 0.550".

If your barrel does not look like this, then you need a muzzle-indexed 1/2-28 piston. We will have a "B" version of the 1/2-28 piston available soon. In the meantime, please contact us for a solution.

NOTES FOR USING REGULAR FULL POWER AMMUNITION: If your pistol does not quite return to battery or does not fully eject empty cases, you may need a slightly weaker than stock recoil spring in your pistol.

NOTES FOR USING "EXTRA SUBSONIC" AMMUNITION SUCH AS "HUSH" OR "STELTH": If your pistol exhibits the symptoms listed above for "full power ammunition", does not eject, or does not even unlock, you may need a weaker recoil spring in your pistol.

BOOSTER SPRING LIFETIME

Our special wave-type BOOSTER SPRING is made to exceed the lifetime of other booster springs on the market by a factor of up to about 20x. Our spring will "break in" in the first 50-100 rounds and should have a lifetime during which it provides the original spring constant for a minimum of 1000 rounds, but typically 2000-2500 rounds. The spring will need to be replaced once its free length is less than 1.25 inches.

CLEANING INSTRUCTIONS

Periodically clean the suppressor to remove accumulated carbon. First, completely disassemble the suppressor. The SUPPRESSOR BODY, MODULE, and END CAP should be cleaned using CLR per our normal cleaning instructions (TBAC GENERAL CLEANING INSTRUCTIONS). The REAR CAP, PISTON, BOOSTER SPRING, and FIXED BARREL SPACER can be cleaned by hand using a toothbrush and standard cleaning solvent. Do not soak any steel parts in CLR. Rinse with water, dry, and reassemble.

The shaft of the PISTON where it goes into the REAR CAP should be kept clean and lubed for best operation.

ARMORER LEVEL INSTRUCTIONS

There are no armorer level operations for this suppressor. Please contact TBAC if you need additional service.