These manuals originally sold for $10.00 each.

Now, due to
the worldwide economic collapse, they are my Gift to you.
My hope is that you will enjoy these great little airplanes as
much as I have enjoyed designing them for you.

You may build as many planes as you like.

Sell your planes, or give them away.
Tell ALL your airplane loving friends to come to the site and
get as many of the manuals as they like.

If you enjoy these planes, please help to ensure this site stays
on-line and these airplane manuals remain available for all to
enjoy. Any amount you donate is greatly appreciated.

Every dollar helps!

May God bless you and keep you safe.

Thank You & Enjoy!

Wayne
 Step By Step Construction Plans.
33 Pages With Over 140 Full Color Photos
showing how to build the
Cessna 172 Skyhawk
FROM CANS !

Wing Span: 18 12”

Can be made from most Length: 15”

ET
12 or 16 oz Beverage Cans.
R
Height: 4”

SEC
TOP www.bcair.com
Copyright © 2014 B. C. Air Originals
 Welcome to the B. C. Air Originals Squadron.

This booklet contains complete step by step instructions for building the B. C. Air
Originals - Cessna 172 SkyHawk. Before you start building your first plane it is
suggested that you review the entire set of plan directions. Once you have pre-
viewed the construction steps you should start collecting the cans that you want to
use to make your first plane. These plans are designed to be used with most any 12
or 16 oz. beverage can. Always use clean, unscratched and undented cans for the
best looking planes.

Since the building of these planes requires the cutting of cans and the use of sharp
tools, CHILDREN SHOULD NEVER ATTEMPT THE CONSTRUCTION OF
THESE PLANES WITHOUT ADULT SUPERVISION AND GUIDANCE.
CONSUMER ACCEPTS ALL RESPONSIBILITY FOR ANY INJURY IN-
CURRED IN THE BUILDING OF THESE PLANES.

It is not necessary to follow all the building steps in the order presented. Such as, if
you want to make the Wing, or the Landing Gear first, you can do that and then set
them aside until you need them. However, until you understand the construction of
these planes, it may be easier to follow the steps in the order listed. Your very first
step should be to make a copy of all the templates. All templates are drawn to
scale. Using a sheet of mylar (Clear Plastic) will enable you to re-use your tem-
plates again and again. There is no limit to the number of planes you can build with
these plans.

We, at B. C. Air Originals, will make every effort to assist you in answering any
questions you may have about the construction of these planes. Please feel free to
contact us ANY TIME at command@bcairoriginals.com.

Thank you for your interest in the B. C. Air Originals and have FUN!

D. P. (Wayne) Mathis
 When you print your manuals be sure that your printer is set on it’s MAX
printing area to ensure that all the templates print out to the correct size.
The standard 12 oz Can, here in the US, measures 2 1/2" in diameter. If the
Cans you’re using to make your plane are smaller or larger, then here’s
what you do..... Measure the diameter of your Can and find what percent-
age of 2 1/2" it is.... I.e. If your Can measures only 2 1/4" (in diameter)
then 2 1/4" is = to 90% of 2 1/2" so you would print out all the templates
at 90% instead of at 100%. If your Can measures 3" (in diameter) then 3"
is = to 120% of 2 1/2" so you would print out all of the templates at 120%.
etc.
Some of these models were originally designed in 1984. Since then the
building techniques of these planes has changed over time. I.e. many of the
planes no longer require the use of the wooden former “F-1 & F-2”. We
simply glue the “B-2’s” onto the BACK (BOTTOM) of the Can “B-1” or
use corrugated cardboard in place of the wood. (See http://
www.bcair.com/BT/nwf1.htm and http://www.bcair.com/BT/nf1.htm )
Once you’ve reviewed your manual and you’re ready to start your first
plane, go here > http://www.bcair.com/BT/ < and look over the Builder’s
Tips. These are building tips sent in from builders all over the world. They
will help you to make these planes easier and faster. Bookmark this page as
it is NOT accessible from the main web site.
You can obtain the plastic props used on these planes from your
local Hobby Shop or here’s where I get my props on-line > http://
www3.towerhobbies.com/cgi-bin/wti0091p?&C=QBC&V=MAS <.
Here’s where I get my Wooden Propellers on-line > http://
http://www3.towerhobbies.com/cgi-bin/wti0097p?
www3.towerhobbies.com/cgi-bin/
wt0
i097p?FVSEARCH=PROPELLERS+++&CATEGORY=QB&MANUFACTURER=TOP&submti=Submti+AdvancedSearch
FVSEARCH=PROPELLERS+++&CATEGORY=QB&MANUFACTURER=TOP&submit=Submit+AdvancedSearch
<
Any 5-7" prop, with any pitch, will work on these planes.
The following is a list of tools and materials I use to build these planes.
You may find that you do not need all of the tools that I use.
Use whatever works best for you.

Push Pin.
Hot glue gun.
Awl (old screw driver sharpened to a point).
Wire cutter. Rat-Tail-File
X-acto knife (hobby knife) (box opener).
Scissors
Small Paper Cutter, Ruler (straight edge).
Felt tip pen (any color).
Needle nose pliers.

Materials -

Aluminum Cans (beer, pop, soda, juice, etc) any 12 oz. size will work.
Bottle caps.
Corrugated Cardboard.
Tape (any kind) & Glue (2-Part Epoxy works best).
Mylar (Clear plastic).
Copper Coated Welding Rod, Music Wire or any other straight wire .
(2 sizes - 1/16” & 3/32”)
 Cutting Cans
The building of these planes requires that the Tops and/or Bottoms of beverage cans be
cut off. While you can decide for yourself which method you use to accomplish this,
most builders use a Dremal® Tool in a fashion similar to that shown below.

What I’ve done here is taken a piece of

board wood (aprox 12” x 15” x 3/4”) and to
it I’ve attached (screw or glue) Two Blocks
of wood (2” x 2” x 5”) and Two Rails of
wood (1” x 1” x 10”)

Using a Hose Clamp, I’ve secured my

Dremal® Tool to the board. The two
guide rails are used to cradle the can.

A cutting wheel is used to cut the

Bottom and the Top off the Cans.

In ALL cases, cut

the Bottom off the
Can FIRST, then
cut the Top off.
Get as much of the
Can as possable.

Again, you can use any other method at your disposal to remove the Tops and Bottoms
of the cans. Use whatever means you feel most comfortable with.
ALWAYS USE PROTECTIVE HAND & EYE GEAR WHEN CUTTING CANS!

SEE ALL THE BUILDERS TIPS ON-LINE AT > www.bcair.com/BT

 Another Way Of Cutting Cans
(This is the method I used to make this Plane.)

Once you’ve selected which Cans your plane will be made out of, take one Can and hold it firmly at
it’s bottom. Using your wire snips, cut through the ring at the top of the Can.

Now grab the ring with your wire snips and PULL the top off the Can. The top will normally tare off
right where the Can begins to taper inward to the ring.

Continue PULLING until the top of the Can comes off. Then cut down the side of the Can with your
scissors. Next use a smaller scissor to cut the bottom off the Can.

Use a straight edge, or a paper

cutter to trim the edges smooth.

Trim Can to 3 5/8” x 8 1/4”

6
SEE ALL THE BUILDERS TIPS ON-LINE AT > www.bcair.com/BT
This Plane takes a total of 17 Cans to make. It is designed to be
made from most 12 oz. beverage Cans but can easily be made
from the larger 16 oz. Cans.

Pull Tab

STEP # 1

Once you’ve selected which Cans you’re going to make your Plane out of, remove all the Pull Tabs
from the Cans and cut the Tops and the Bottoms off all Cans and open them up as shown here.

For this plane I’m going to use Dr. Pepper and Diet Dr. Pepper Cans. The Regular Dr. Pepper
Cans will be used for the Plane’s Body, the VS, and the Wheel Pants while the Diet Dr. Pepper
Cans will be used for the Main Wing, the Wing Struts and the HS.

You can mix and match your Cans any way you like.

Set your cut Cans aside for use later in the building process.
 Flatten
STEP # 2
Flatten Flatten
Plane’s Cabin

Cut Template # 1 (Page 31) from corrugated

<---Corrugation Runs--->
cardboard and Score, on the INSIDE, where
<---Corrugation Runs--->

A A
Score indicated.
Lines
in Flatten corrugation where indicated on the
Blue Front of the Plane’s Cabin.
B B
Use your Push Pin and make Holes A & B
where indicated.

STEP # 3

Bring up the Sides and the Back of the Plane’s Cabin

and glue in place. (I used Hot Glue for this)

The Back glues to the BACK of the Sides.

(Also see photos in Step # 6)
1

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 <---Corrugation Runs--->
STEP # 4
Cut TWO Template # 2 (Page 31)
from corrugated cardboard and glue #2
together as shown. Make Hole C
through BOTH # 2’s
<---Corrugation Runs--->

STEP # 5
Glue Template # 2 onto the
FRONT of Template # 1 as

1 shown.

Glue the Sides First. #2

#2 Then bring up the Bottom and
glue in place.

Trim off excess cardboard

from the Bottom.

Glue on the INSIDE. (I used Hot Glue for this)

Your Plane’s Cabin should now look like this.

#2

1 #2
1
 1
1
3 3

STEP # 6
Cut Template # 3 (Page 31) from corrugated
cardboard and glue in place into # 1 as shown.
(I used Hot Glue for this.)

www.bcair.com

2 2

3 3

1 1

Note that the Back of # 1 glues to the BACK of the Sides of # 1.

 STEP # 7
1
Use your X-Acto Knife and cut the holes in
the Back of # 1 and in # 3 where indicated.
3

STEP # 8

Cut TWO Template # 4 (Page 31) from corrugated

cardboard and glue them together.
4
Then glue them to the INSIDE of # 1 as shown.

3
<---Corrugation Runs--->

1
4 4

<---Corrugation Runs--->
2
 6
<----Corrugation Runs---->

STEP # 9 Cut Templates # 5 & # 6 (Page 32) from corrugated cardboard and glue 6 on Top of 5 as shown.

6
Top of Wing
5
STEP # 10 Cover the Bottom of the Wing with Cans from Step # 1 as shown.

5
Bottom of Wing

Glue Cans to the Bottom of the Wing and Trim Cans as needed to get the shape of the Wing.

6
Top of Wing
5
Cover the Outsides of the Bottom of the Wing First

Bottom of Wing

Cover the Middle of the Bottom of the Wing Last.

6
Top of Wing
5
 6

5
6 5
Top of Wing

STEP # 11 1
Take TWO Roofing Nails (Shingle Nails or similar Nails)
and insert them into the Top of the Wing as shown.

Center the Wing in position, on Top of the Plane’s Cabin,

and push the Nails through the Top of Template # 4.

Then remove the Wing and go onto Step # 12.

1 4
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 STEP # 12

Now cover the Top of the Wing with Cans, from Step # 1. Cover the Outside of the Wing First.

Trim the Cans just enough to get the Top Cans to Fold Over the Leading and Trailing Edges of the Wing.

Cover the Middle part of the Top Wing Last.

Finished Wing. Top View. Bottom View. Now set the Wing aside.

Note the Nails sticking through the Bottom of the Wing.

 STEP # 13
Glue a Can to the
Bottom of 1 as
shown.

Note that the Can

overlaps 1, in the
Back, by 1/8”.

Mark the Inside of the Can and Trim, leaving 1/4” 1

to Fold over the Top of 4 and the Sides of 1 as
shown.

4
. 4
B
. 1 Glue the Can to the
Sides of 1 as shown.

.
A

1 . B
A
Your Plane should
now look like this.

Make and Enlarge Holes

1 A & B on Both sides of 1
4 1 at this time. 4
. . 1
1 .
A

B
A

B
.
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 STEP # 14
Merry Two Cans, from Step # 1,
together as shown here.

Can
Cellophane Tape
Double-Sided Tape

Glue on INSIDE
(Use Contact Cement)

STEP # 15
Cut Template # 7 (Page 33) from the Two Cans
you married together in Step 14 and shape into a
Cone. Glue Tab on the INSIDE.

7 The Split where the Cans meet should

be on the TOP Side of the Cone.

7
 8 8
8

STEP # 16

Cut TWO Template # 8, (Page 33), from corrugated cardboard and

glue them together.

NOTE: Cut One 8 on the OUTSIDE of the line and cut One 8 on the
INSIDE of the line so that One 8 is slightly smaller than the other.

Cut the Hole through BOTH 8’s and glue the 8’s into 7 as shown. 8

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7
8 8
 NOTE:
1 7
1/2”

STEP # 17

Glue the Tail Cone (7) onto the 1

1 Back End of 1 as shown.
7
7

STEP # 18

Cut Template # 9, (Page

33), from Can and glue it
to the Bottom of 1 as
shown.

Glue the Sides of 9 to the

9
Sides of 1 as shown.

Trim the Bottom of 9 9

9 as shown and glue to
the Bottom of 1 as
shown.
 STEP # 19
Glue 15 Pennies, or their equivalent weight, into the Front Bottom

. of the Plane’s Nose Cone. DO NOT BLOCK THE HOLES IN

TEMPLATES 2 or 3.

10
10

2 9
9 2 STEP # 20

Cut Template # 10, (Page

33), from Can and glue it
to the TOP of 1 and 2 as
shown.

Fold 10 over the Sides of

9 and glue in place.

Trim excess Front of 10

where needed.

10
10
9
9 2
2
 STEP # 21
Take a piece of 3/32” Rod, 7” long, and bend it as shown below.

Insert the Rod through Holes B in 1 and, working through the

hole in the top of 1, glue the Landing Gear in place INSIDE as
shown at the Left.

2”

1 1/2” 1 1/2”

Rod will bend at this point

for the Wheel Axle.
1” 1”

1 7
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A B

1/2”

Landing Gear should slant

FORWARD 1/2”

Landing Gear will bend Landing Gear will bend

here for Wheel Axle. here for Wheel Axle.

1 1/2”

1” Distance should be 4”. 1”

 STEP # 22

Trace Template # 11,

(Page 33), onto the
Bottom INSIDE of a
Can and cut it out as
11
shown.

STEP # 23

Take a piece of 3/32” Rod, 17” long, and put a 1 1/2” right angle bend on one end of it. Insert the Rod through the Back
End of 7 and out through the Hole in 2. Put some Paint, or Nail Pulish, on the tip of the Rod as shown. Now place 11 into
position on the Front of the Plane’s Nose and push the Rod up against the INSIDE of 11. The Paint spot, on the INSIDE
of 11, will show you where to make the Hole for the Rod to go through 11.

10

7
2

11
STEP # 24
OUTSIDE OF 11
After you’ve made the
Hole in 11, glue 11 onto
the Front of the Plane.

11 10
INSIDE OF 11
11
 STEP # 25
Cut Template # 12, (Page 32),
from corrugated cardboard and
cover with Cans in the same way

12 that you covered the Wing.

12

STEP # 26

Take a piece of 3/
32: Rod, 1” long,
and glue it into the
Forward part of
12 as shown.
12 Make a 3/32” 12
Hole in the Top of
7 where needed to
insert the 1” Rod.
7
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STEP # 27

Make a 3/32” Hole on Both Sides of 7, 1” from the

Back End. This is where you’ll insert a 3/32” Rod,
4” long, for the Horizontal Stabilizers to glue onto
STEP # 28
(Step # 35).
Glue 12 in place as shown.

7
1”
12
7
 STEP # 29
Make several scratches in
the Top of 4 as shown.
This will give the glue
something to anchor to
when you attach the Wing.

STEP # 30 7
4 Make several Holes in
the Top of 7 as shown.
This will give the glue
something to anchor to
when you attach the Rear
Windshield.

STEP # 31
Cut Template 13, (Page 32),
out of a piece of Can.
13

STEP # 32

Glue the Rear Windshield (13) in place on Top of 7 as shown.

Make several Scratches in the Sides of 1 as shown, (This will give

the glue something to anchor to) and glue 13 in place to the Sides
of 1 as shown.
13

7
Rear Top View of Plane
Scratches
Scratches

13 13
1 7 7 1
Left Side of Plane Right Side of Plane
 12 14
7 14 12
7
STEP # 33 Cut Template # 14, (Page 31), from a Can and glue it in place on TOP of 7 and 12 as shown.
14 should cover the split in 7.

STEP # 34 Take the completed Wing (from Step 12) and glue it to the Top of 4 as shown.

Top Back View

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 STEP # 35
Cut TWO Template #
15 15 15, (Page 32), from
corrugated cardboard
and cover them with
Cans as you did the 15
Wing.

15 15

STEP # 36

7
Insert a 3/32” Rod, 4” long, into the Holes on Both
Sides of 7 that you made in Step # 27 and glue Both
15 15 15’s onto them as shown.

Your Plane should now look like this.

 STEP # 37
16 Cut Template # 16, (Page 32), from
Can and glue it in place as shown.

16 16

16
13

16

17 17 STEP # 38

Cut TWO Template #

17, (Page 33), from
Can and glue them in
place on the Top of
the Wing as shown.

13
 16
16
13 16
17 17
STEP # 39

Tape off All windows as shown.

16
13 16 13

For the Wheels I used, 3/4” Sullivan Tailwheels - No. 351, from Tower Hobbies.

STEP # 40
You can also make your wheels from Bottle
NWLG Caps. Take Two Caps and put a 3/32” hole
Take a piece of 3/32” Rod, in the center of each cap. Glue Two Caps
3 1/2” long, and bend it as together to make one wheel.
shown here. 2 3/8”

Glue the NWLG into the

UNDERSIDE of 9, 1 1/4”
STEP # 41
Back from the Front of 11. Glue a small piece of Tubing in the
1/4” bottom of 9 as an Exhaust Pipe.

Glue a small bubble of Hot

3/8” Glue onto the bottom of 11
Install the Wheels onto as a Landing Light.
the Landing Gear. 1/2”

11
9

1 1/2”

9
 STEP # 42
Take a piece of 3/32” Rod, 10 1/4” long and bend it as shown here. Insert the Rod through Holes A, in 1.
Tip each end of the Rod with an Electrical Connector (you can use either a round one or a forked one).
Mark appropriate slits in the Underside of the Wing and glue the EC into the Wing as shown.

Use a Black Marking Pen and darken the area

on the Front of 11 to show Air Intake Holes.

EC’s

Install Prop and Spinner

Nut onto the Prop Shaft
and cut off excess Shaft.
11

Glue EC’s into

the slits in the
Wing.

I used a Three-Blade 5x3

(13x8 cm) Prop from Tower
Hobbies. Part # MA0530TE
and painted it Silver.
 STEP # 43 - OPTIONAL

Cut TWO Template # 18, (Page 33), from

Cans and cover the Landing Gear.

STEP # 44 - OPTIONAL
Cut Two Template # 19, (Page 31), from Cans and cover the Wing Struts.
 STEP # 45 - Optional
Cut THREE Template # 20, (Page 31), shape into Wheel Pants and glue onto the Landing Gear.

Right Wheel
Nose Wheel
20
Left Wheel

20 20

STEP # 46 - Optional
Glue Two pieces of 1/16” Rod, 1” long, into
the Top of the Wing as Radio Antennas.

STEP # 47 - MANDATORY Show your finished Plane to ALL your friends !

Your B. C. Air Originals Cessna 172 Skyhawk is now complete.
 Flatten
Flatten Corrugation Flatten
Corrugation Corrugation

Template # 19
A A

<---- Corrugation Runs ---->

<---- Corrugation Runs ---->

Template # 1

B 7 3/4”
B

.
Prop Shaft Hole C

Template # 2
Template # 4

Template # 14
Template # 3

<-- Corrugation Runs --> Template # 20

31
 X
Template # 6
Tape TWO of these Templates together at X & X and Y & Y to get ONE Complete Template.

Template # 5
9 1/4”

Y
Template # 16
Template # 12
Template # 15

Template # 13

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32
 Score to this Point ONLY

Template # 7
Template # 17

TC .
B
TA
6 1/2”

Template # 11

Template # 8
Template # 10

Template # 9

.
Nose Wheel Landing Gear Hole
Template # 18
(2-Required)

33
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