3D HANGAR

Bolt PWC · R5 hardware changes

R5.1 · gear mounts fit without pads

R5.1 closes the gear-deck gap in the four printed mounts. Each bearing base is now 7 mm thick and seats directly against the existing plywood deck. No separate bearing pads are needed. Use the same M4×30 and M3×25 deck bolts with washers and locknuts; the base + deck + doubler stack is 7+6+6 = 19 mm. Check actual washer thickness and full locknut engagement. Keep the supplied print orientations and inspect the sliced layers with supports off before printing.

R5 gear deck hardware: four M4×30 bolts, eight 18 mm OD M4 steel washers and four M4 locknuts; add four M3×25 bolts, eight 7 mm OD M3 washers and four M3 locknuts. The original fork fasteners remain separate. Deck/doubler thickness is 6+6 mm; the new printed base is 6 mm.

Interactive 3D viewerFree · name and email required

  1. Print the four gear nodes in their supplied orientations. Each side now uses one front node at X340 and one rear node at X410. Keep the PWC-specific carbon leg lengths and lower nodes.
  2. Print the drilling template at 100% and verify its 50 mm scale bar. Align the four existing M4 hole centers at X340/410,Y±25. Add four Ø3.3 mm anti-rotation holes at X356/394,Y±25 through the 6 mm deck and 6 mm plywood doubler. The 110×80 mm doubler stays centered at X375,Y0.
  3. Use four M4×30 bolts with 18 mm OD load-spreading washers on both faces and locknuts. Add four M3×25 bolts, two 7 mm OD washers and one locknut each. Check the 7+6+6 mm printed/deck/doubler stack, real washer thickness and full locking engagement. Do not rely on one bolt per block.
  4. Use both matching R5 F02 body sections and the R5 X385 collar; clearance channels remain open behind the gear gussets. Retain the original hardwood deck rails and bond instructions.

In the download: Full-size PWC drilling template