Professional Documents
Culture Documents
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.
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.
North American
P-51D
Wingspan: 17”
Length: 15”
Height: 5”
Mustang
ET
Can be made from most 12
R
or 16 oz Beverage Cans.
SEC
TOP www.bcair.com
Copyright © 2007 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 P-51D Mustang. Before you start building your first plane it is sug-
gested that you review the entire set of plan directions. Once you have previewed
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 any 12 oz. 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 Wheels 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 templates 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.
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”)
Hazel Nuts (Acorn Nuts, Cap Nuts, Toothpaste Caps).
Screws, Nuts and Bolts.
Wire clip (speed nut).
2
Using two hole saws (the larger one is 2 3/4” and the smaller one is 1 5/8”) cut two
EACH circles from any kind of wood that is 3/4” thick. Soft Pine like that used to
make wooden pallets works best. These four wooden circles will now become F-1’s
& F-2’s.
Using a wood rasp (or similar tool) taper both F-1’s & F-2’s as shown above.
The “Perfect” F-1 and F-2 would have the dimensions shown at right. But they
don’t have to be perfect as long as F-1 DOES NOT EXCEED 2 1/2” in diameter.
Work F-1 down to a size (approx. a little less than 2 1/2” in diameter) that will
allow it (once wrapped with cans B-2C & B-3C Steps # 5 - # 7) to fit inside Can
B-1 (Step # 2).
NOTE: You can also use a jigsaw or any other method at your disposal
to obtain F-1’s & F-2’s as long as you end up with the same dimensions.
www.bcair.com
Cutting Cans
The building of these planes requires that both 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 above. The
Dremal® is secured to a board with the use of a hose clamp. Two guide rails are used to
cradle the can. A cutting wheel is used to cut the Bottom of the can off first, and then the
Top is cut off. 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.
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.
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!
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.
STEP # 2
Select One of the Cans from Step # 1 and designate
it as the planes main body Can. Trim BOTH ends
so that they’ll be smooth.
This Can will become B-1.
B-1
www.bcair.com
STEP # 3
3 5/8”
Using your scissors, open up the
remaining 11 Cans as shown
here.
STEP # 4
Take one of Can you opened up in Step #
3 5/8” 3 and cut it as shown here. This will be-
come Can B-2C.
B-2C Cut Off & Discard.
1 3/8” www.bcair.com
STEP # 5
F-2
F-1 Staple one F-1 & one
F-2 to Can B-2C as
B-2C shown.
F-2
THIS WILL NOW
BECOME B-2
B-2C
F-1 STAPLE
STAPLE
B-2C
B-2
Cut Off
F-1 excess Can
F-2
STEP # 6
1 3/8” Take another Can you opened up in
Step # 3 and cut it as shown here.
This will become Can B-3C.
B-3C
F-1
B-3C
F-1
Staple
Staple
STEP # 8
Wrap B-3C around F-1 & F-2 and
B-3C
staple as shown. Trim off any
excess Can extending beyond F-1 B-3
& F-2 as shown to the right.>
This now becomes B-3.
Staple
F-2
Use a Black Marker
F-2
1/2”
and color the face of
F-2 (in B-3). F-2
F-2 www.bcair.com
STEP # 9
You now have B-1, B-2 & B-3 as shown here.
F-1’s
F-2
F-2
B-1 B-3
B-2
STEP # 10
Insert B-2 & B-3 into B-1 and secure in place with SIX Staples as shown here.
Staples
www.bcair.com
Staple Staple
Bottom View
Top View
STEP # 11
B-1 B-2
A Holes B
This edge flush with FRONT of B-1
SLIT 4
A Holes B
2
SLITS
X 3
Y
TEMPLATE # 1
STEP # 12
Push Pin
B-2
Bottom of Plane
B-3
B-1
STEP # 13
Slits“3”
B-2
Top of Plane
STEP # 14 Cut TWO pieces of corrugated cardboard as shown below.
WCB 1”
CBAF
7”
STEP # 15
1 1/2”
7 1/2” 7 1/2”
Take Two pieces of 3/32” Rod 15” long and bend them as shown here. These will become the
Forward Wing Spar (FWS) and the Aft Wing Spar (AWS).
www.bcair.com
CBAF CBAF
WCB
B-1 WCB
B-2
STEP # 16 Insert the FWS into Holes “A” in B-1 and insert the AWS into Holes “B” in B-1.
Glue or tape both CBAF to the Top Leading Edge of the wing as shown.
B-3
123456789012345678901234567890121234567890123456
123456789012345678901234567890121234567890123456
123456789012345678901234567890121234567890123456
123456789012345678901234567890121234567890123456
123456789012345678901234567890121234567890123456
123456789012345678901234567890121234567890123456
WCB
STEP # 17
Place a123456789012345678901
strip of Double Face
123456789012345678901
Tape 123456789012345678901 on the
123456789012345678901
Cover the Under side of the B-2 UNDER SIDE of the WCB
wing with One Can. as shown here.
of CBAF.
Wrap the wing with one of B-2
the Cans that you opened up
in Step # 3 as shown here.
1234567890123456789012 1 Can
1234567890123456789012
1234567890123456789012
1234567890123456789012
CBAF
1234567890123456789012
1234567890123456789012
1234567890123456789012
1234567890123456789012
FWS
WCB (SIDE VIEW OF WING) AWS
1 Can
NOTE: Top Can overlaps Double face tape on Bottom Bottom Can will be longer than
Bottom Can by approx. 1/4”. of WCB to hold Can in place. Top Can. Trim after securing.
Template # 2
Staples
CBAF
WCB B-2
Staples
STEP # 19
With both the upper and lower Cans secured and the wing pattern traced onto the wing,
trim the excess Can from the wing. Repeat Steps 17 & 18 on the other wing.
Top View
Staples
B-2
www.bcair.com
Staples
STEP # 20
Cut TWO Templates # 3 out of Two
VERTICAL Cans you opened up in Step # 3. Be
STABILIZER sure to FLIP the template to get a
. .
matching pattern. Cut the TAB
VS OFF One of the patterns
TEMPLATE # 3
TAIL CONE
TEMPLATE # 4
.
TAB
VSCB
E
STEP # 21
Take a piece of 3/32” Rod 17” long and put a “Hook” in one end
of it. This will become the Propeller Shaft (PS). Insert the Hook
End of PS into Hole “E” of VSCB and crimp the Hook closed.
VS
VS
. .
C
. . VSCB
E
PS
Match up the two VS patterns and Staples
STEP # 22
staple in the 6 positions shown.
STEP # 23
Insert VSCB between the two VS patterns and
form the Tail Cone. The Tab goes on the
INSIDE of the Tail Cone. Use a piece of cello-
123456789012345678
VS
123456789012345678
phane tape 123456789012345678 to secure the OUT-
123456789012345678
Staples
SIDE of the Tail Cone and Glue or Epoxy the
INSIDE of the Tail Cone together.
TAB
VS
1234567890123456789012345678901212345678901234567890123456789012
1234567890123456789012345678901212345678901234567890123456789012
1234567890123456789012345678901212345678901234567890123456789012
1234567890123456789012345678901212345678901234567890123456789012
1234567890123456789012345678901212345678901234567890123456789012
1234567890123456789012345678901212345678901234567890123456789012
1234567890123456789012345678901212345678901234567890123456789012
1234567890123456789012345678901212345678901234567890123456789012
1234567890123456789012345678901212345678901234567890123456789012
123456789012345678901234567890121234567890123456789
1234567890123456789012345678901212345678901234567890123456789012
123456789012345678901234567890121234567890123456789
123456789012345678901234567890121234567890123456789
123456789012345678901234567890121234567890123456789
123456789012345678901234567890121234567890123456789
VS
VSCB
PS Cellophane Tape
STEP # 24
Insert the PS through the pilot hole in F-2
VS
B-2 F-2
(B-2), through the pilot hole in F-1 (B-2),
through the pilot hole in F-1 (B-3) and out
through the pilot hole in F-2 (B-3).
VS Pull the Tail Cone up over the back end of
B-2 and hold in place with a Wire Clip on
the end of the PS as shown.
B-3
F-2
VS
Wire Clip
B-2
PS
STEP # 25
Cut a small piece of Can
Fold Line
into a triangle as shown
at the left and glue/epoxy
VS
it to the VS as shown at
the right.
STEP # 26
<--- Corrugation Runs ---> Cut TWO pieces of cardboard to the shape of the HSCB
TEMPLATE # 5 at the Left.
HSCB
Cut One Can in half and fold each half over as shown
below.
HSCB
123456789012345678901
123456789012345678901
123456789012345678901
123456789012345678901
123456789012345678901
123456789012345678901
Place a strip of Double-Sided Tape 123456789012345678901
123456789012345678901 on the UNDERSIDE of each HSCB.
Insert the HSCB into the bent Can then staple and trim as shown below.
These will be the Horizontal Stabilizers (HS).
Staple
HS HS
Staple
Staples Staples
Hole “C”
VS STEP # 27
Hole “D”
VS
Push both HS’s against the VS
and hold in place until glue/
HS HS epoxy is dry.
TEMPLATE # 6
A A
STEP # 28
B
CPC B
HR STEP # 30
B-1
HR
Put a small amount of glue/epoxy on the
ends of the HR and insert the HR into
Slits 3 on the top of B-1.
B-1
B-1 STEP # 31
Slit 1 Slit 2
Place Front CPC Tabs into Slits 1 & 2 (in B-1) and
Mark where the Rear CPC Tab Slit is to be made in
B-2.
CPC
Slit 1
B-2
Make the Rear CPC Tab Slit, put
B-2
some glue/epoxy on each CPC Tab B-1
and insert them into their appropriate
Slits. Hold CPC in place with a
piece of tape until glue/epoxy is dry.
STEP # 32
Tab 1 Tab 2
Duct Tape
B A
TEMPLATE # 7
STEP # 34
AS
BA Tab 3 Tab 4
Tab 5 Tab 6
Slit 4
AS
B-1
AS B-2
Tab 6 Tab 4 Tab 2
STEP # 35
Pin a strip of Duct Tape, 1/2” wide by 6” long, onto a
piece of cardboard. STICKY SIDE UP.
Take SIX Electricial Connectors (I use Ring Terminals
4-6 Stud) and bend them as shown here. These will
become the Engine Exhaust Pipes EEP.
Place the 6 EEP
onto the Duct Tape
as shown.
Side Views
Epoxy/glue the
EEP’s together.
www.bcair.com
STEP # 36
3/8”
B-3 B-3
EEP
3/8”
EEP
PS
STEP # 37
STEP # 38
2 3/4” 2 3/4”
If you’re going to display your plane with “Gear-Up”
(NO LANDING GEAR) then you can skip Steps 39,
40, 41, 42, 43, 44, 45 and go directly to Step # 46.
STEP # 39
Take FOUR Bottle caps and put
a 3/32” hole in the center of each
cap. Glue/epoxy TWO caps
together to make one wheel.
www.bcair.com
F
1”
E 1”
1 1/4”
D STEP # 40
C 1/2”
C C
B TW
A A
STEP # 41
2 1/4” 2 1/4”
Make a 3/32” hole in
the UNDERSIDE Can
of both wings 2 1/4”
from B-1 and at the
edge of the Top Wing
B-1
Covering Can as
shown to the Right. “F” “F”
The hole is through the
Underside Can ONLY.
STEP # 42
Mount the Main
Landing Gear
Wheels onto “A”
and hold in place
with an Acorn Nut.
STEP # 43
Cut TWO pieces of Can to the shape shown at the Right >
These will be the Main Landing Gear Doors (MLGD). Put a
small amount of glue/epoxy on the small end of the MLGD
and secure it to the underside of the wing as shown here.
B-2
STEP # 44
Drill a 3/32” hole in the
bottom of F-2 (in B-2). .
STEP # 45
Bend a piece of Can 1” x 3/4” as
shown and insert the TW into it.
Glue/epoxy the TW and the Tail
Wheel Gear Door to the bottom
of the Tail Section as shown.
STEP # 46
If you can find a Four Blade Prop you can skip
this step.
You can make a Four Blade Prop by notching a
Two Blade Prop on the Bottom Side of Center and
notching another Two Blade Prop on the Top Side
of Center as shown. Glue/epoxy the two props
together.
On this plane I used Two props (to
make One 4-blade prop) from Tower
Hobbies (www.towerhobbies.com).
Prop # LXZ951
STEP # 47
STEP # 49
Install the Prop onto the PS and secure in place with a nut
and wire clip or some other means. Cut off excess PS.
STEP # 50
Glue Spinner
Add Nose Art.
Cut and glue/epoxy a to Prop.
small piece of Can as the Add Victory Flags.
Radio Antenna.