Every dollar helps! These manuals are the culmination of more then 10 years of design and publication and formally sold for $10.00 each. With 54 different manuals available, that’s a $540.00 value. 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. May God bless you and keep you safe. Thank You & Enjoy! Wayne
Transcript
Every dollar helps!
These manuals are the culmination of more then 10 years of designand publication and formally sold for $10.00 each. With 54 different
manuals available, that’s a $540.00 value.
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 asmany of the manuals as they like.
If you enjoy these planes, please help to ensure this site stays on-lineand these airplane manuals remain available for all to enjoy. Any
Step By Step Construction Plans33 Pages With Over 150 Full Color Photos showing how to build the
Can be made from most 12or 16 oz Beverage Cans.
Wingspan: 13”Length: 20”Height: 7”
McDonald/Douglas
F-4Phantom II
Welcome to the B. C. Air Originals Squadron.
This booklet contains complete step by step instructions for building the B. C. AirOriginals Mc Donald/Douglas F-4 Phantom II. Before you start building yourfirst plane it is suggested that you review the entire set of plan directions. Once youhave previewed the construction steps you should start collecting the cans that youwant to use to make your first plane. These plans are designed to be used with any12 oz. or 16 oz. beverage can. Always use clean, unscratched and undented cans forthe best looking planes.
Since the building of these planes requires the cutting of cans and the use of sharptools, CHILDREN SHOULD NEVER ATTEMPT THE CONSTRUCTION OFTHESE 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, ifyou want to make the Wheels first, you can do that and then set them aside untilyou need them. However, until you understand the construction of these planes, itmay be easier to follow the steps in the order listed. Your very first step should beto make a copy of all the templates. All templates are drawn to scale. Using asheet of mylar (Clear Plastic) will enable you to re-use your templates again andagain. 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 anyquestions you may have about the construction of these planes. Please feel free tocontact us ANY TIME at [email protected].
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 MAXprinting 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 theCans you’re using to make your plane are smaller or larger, then here’swhat 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 templatesat 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 thebuilding techniques of these planes has changed over time. I.e. many of theplanes no longer require the use of the wooden former “F-1 & F-2”. Wesimply glue the “B-2’s” onto the BACK (BOTTOM) of the Can “B-1” oruse 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 firstplane, go here > http://www.bcair.com/BT/ < and look over the Builder’sTips. These are building tips sent in from builders all over the world. Theywill help you to make these planes easier and faster. Bookmark this page asit is NOT accessible from the main web site.You can obtain the plastic props used on these planes from yourlocal 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://www3.towerhobbies.com/cgi-bin/wti0097p?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.
Pliers.
Push Pin.Hot glue gun.Awl (old screw driver sharpened to a point).Wire cutter.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”)Hazel Nuts (Acorn Nuts, Cap Nuts, Toothpaste Caps).Screws, Nuts and Bolts.Wire clip (speed nut).
2
Cutting CansThe building of these planes requires that the Tops and/or Bottoms of beverage cans becut 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.
SEE ALL THE BUILDERS TIPS ON-LINE AT > www.bcair.com/BT
What I’ve done here is taken a piece ofboard wood (aprox 12” x 15” x 3/4”) and toit I’ve attached (screw or glue) Two Blocksof wood (2” x 2” x 5”) and Two Rails ofwood (1” x 1” x 10”)
Using a Hose Clamp, I’ve secured myDremal® Tool to the board. The twoguide rails are used to cradle the can.
A cutting wheel is used to cut theBottom and the Top off the Cans.
Again, you can use any other method at your disposal to remove the Tops and Bottoms ofthe cans. Use whatever means you feel most comfortable with.ALWAYS USE PROTECTIVE HAND & EYE GEAR WHEN CUTTING CANS!
In ALL cases, cutthe Bottom off theCan FIRST, thencut the Top off.Get as much of theCan as possible.
Another Way Of Cutting Cans
Once you’ve selected which Cans your plane will be made out of, take one Can and hold it firmly atit’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 offright 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 yourscissors. Next use a smaller scissor to cut the bottom off the Can.
Use a straight edge, or a papercutter to trim the edges smooth.
Trim Can to 3 5/8” x 8 1/4”
SEE ALL THE BUILDERS TIPS ON-LINE AT > www.bcair.com/BT
Cutting Cans
The building of these planes requires that both the Tops and/or Bottoms of beverage cansbe 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. TheDremal® is secured to a board with the use of a hose clamp. Two guide rails are used tocradle the can. A cutting wheel is used to cut the Bottom of the can off first, and then theTop is cut off. Again, you can use any other method at your disposal to remove the Topsand Bottoms of the cans. Use whatever means you feel most comfortable with.
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STEP # 1
Once you’ve decided which Cans yourplane will be made from, cut the Topsand Bottoms off 28 Cans.
If you’re using 12 oz Cans, to buildyour plane, get as much of the can aspossible.
STEP # 2
Use your Scissors and openup 26 of the Cans as shownhere.
3 5/8”
Keep TWO Cans intact as shown here >
STEP # 3 Take One of the TWO Cans that you left intact and wrap apiece of paper ( 3 5/8” x 8 1/4” ) around it as shown here.
Draw a line around the Can at BOTH ends of the paper.Then remove the paper from the Can and trim the Canedges smooth.
STEP # 4 Take Template F-1 (Page 31) and cut SIX ( 6 ) F-1’s from coragated cardboard
Be sure to mark theCenter Line on all F-1’s
F-1F-1
STEP # 5Using your Hot Glue Gun, put a beed of glue around the edge of ALL SixF-1’s. (You’re NOT increasing the size of the F-1, you’re just giving theedge something to grab the Can with.)
STEP # 6
Take One of the Cansfrom Step # 3 and stand itup on a flat surface. DropOne of the F-1’s into itand tamp it into place withthe handle of your Screw-driver as shown here >
F-1
F-1
You will need at least 3 5/8” of usable Can.
Repeat on second Can.
STEP # 7F-1
F-1When you have F-1 where you want it,epoxy it to the INSIDE of the Can.
Inside View
Front View
STEP # 8Take another of the F-1’s and cut ahole in the center large enough foryou to get your little finger in it asshown at the left.
Insert this F-1 into the Can andmanipulate it into place with yourfinger through the hole.
Be sure to line up the CenterLines of BOTH F-1’s
Draw Center Lines on Can Top & Bottom
STEP # 9
Once you have the second F-1 in placeuse a bent piece of Rod to apply epoxyon the INSIDE of the Can (through thehole in F-1) and secure the F-1 in place.
F-1F-1
F-1
F-1
F-1
B-1
B-2 B-1
B-1B-2
B-1 B-1This will now be B-1.
Front View
Back View
Side View
STEP # 10 Repeat Steps 6, 7, 8 & 9 to get B-2.
STEP # 11 Epoxy B-1 and B-2 together.
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STEP # 12
Cut Template B-3 (Page 31) from Oneof the Cans from Step # 2.
Form it into a cone matching up A with A and Bwith B. Use Clear Cellophane Tape to hold it’sshape.
Tape it on the INSIDE as well as on the OUTSIDE.
The Can DOES NOT overlap itself but rather butts up against itself.
B-3
STEP # 13
Cut Template F-4 (Page 31)from a piece of corrugatedcardboard and put a beed of HotGlue around the edge as you didwith F-1 in Step # 5.
Drop F-4 into B-3 and push it intoplace. Once you have it where youwant it, epoxy F-4 to the INSIDE ofB-3.
STEP # 14
F-4 F-4
F-4
B-3
B-3
B-3
F-4
Epoxy F-4 on BOTH sides INSIDE B-3.
Draw Center Line on Top of B-3.
F-4
STEP # 15F-1F-1
B-3
Take One of the F-1’sfrom Step # 4 and afterputting a hole in it, toaccommodate your finger,fit it into B-3 as shownhere. When you have itwhere you want it useyour bent piece of Rod toepoxy it in place on theINSIDE of B-3.
STEP # 16
Epoxy B-3 to B-2.
B-3 B-2 B-1
B-4
B-4
Cut Template B-4 (Page 31) from one of the Cans fromStep # 2 and form it into a cone matching up A with Aand B with B. Use Clear Cellophane Tape to hold it’sshape.
Tape B-4 on the INSIDEand on the OUTSIDE.
AA
B B
STEP # 17
Can DOES NOT overlap itself butrather butts up against its edges.
STEP # 18 Cut Template F-2 (Page # 31) from a piece of corrugated cardboard and put a beed of hot gluearound it’s edge as you did with F-1 in Step # 5. Drop F-2 into B-4 and push it into place. When you have it whereyou want it epoxy it to the INSIDE of B-4.
F-2 F-2
Draw Center Lineon Top of B-4.
F-2
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STEP # 19
STEP # 20
STEP # 21
Take another F-1 and afteryou’ve put a hole in thecenter, insert it into B-4.When you have it where youwant it epoxy it to the IN-SIDE of B-4 using yout bentpiece of Rod from Step # 9.
F-1F-1
Epoxy B-4 to B-1.
B-4B-1B-2B-3
B-4
Cut Template B-5 (Page 32) from One of the Cans in Step #2 and form it into a cone matching up A with A and B with B.Use cellophane tape to hold it’s shape. This will be be B-5.
B-5
B-5
B-5
A A
BB
STEP # 22
F-3 F-3F-3
Cut F-3 (Page 31) from a piece of corrugated cardboard and put a beed of Hot Glue aroung it’s edge. Whenthe Hot Glue is cool and dry drop F-3 into B-5. When you have it in place, epoxy it to the INSIDE of B-5.
STEP # 23
B-5
B-5
B-5B-4B-1B-2B-3
F-2F-2
Take the Second F-2 andput a beed of Hot Gluearound it’s edge. When theGlue is cool and dry insertF-2 into B-5 and manipulateit into place. Use your bentpiece of Rod to epoxy it tothe INSIDE of B-5.
STEP # 24 Epoxy B-5 to B-4.
STEP # 25
NCNC
NC
NC
NCB-1B-2 B-4B-3
B-5
Tab
Tab
F-3
Cut Template NC (Page32) from one of the Canfrom Step # 2 and shapeit into a cone. Match upA with A and B with B.The TAB goes on theINSIDE of the cone.Use cellophane tape, onthe OUTSIDE of theCone, to hold it’s shape.Epoxy the TAB area onthe INSIDE of the cone.
STEP # 26
Take the second F-3 and epoxy it into the NC.
Epoxy on the INSIDE.
Epoxy NC to B-5.
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A A
BB
STEP # 27
TC TC
TC
TC B-3 B-2 B-1 B-4 B-5 NC
Epoxy on the INSIDE.
Cut Template TC (Page 32) fromone of the Cans from Step # 2.Form it into a cone (TAB goes onthe INSIDE) and hold in placewith cellophane tape on theOUTSIDE of the cone.
STEP # 28
Epoxy TC “over” back of B-3.
STEP # 29
Trace Template # 1 (Page 33) onto a clear piece of mylar (plastic). Cutout and form it into a cylinder (match up A with A and B with B). SlideTemplate # 1 onto your plane until the leading edge of the Template isflush with the FRONT of B-1.
B-1
Template is flush with the FRONT of B-1.
B-1
B-1
Lay your plane on a flat surface and check to see ifHoles A, B, C, & D are ALL THE SAME height fromthe surface. If not, twist the Template until they are andthen insert a Push Pin into each Hole.
A
A
B
B
C
C
D
DMake SLIT # 1 in B-1.
B-1
STEP # 30
Take a piece of 3/32” Rod 12” long and bend it as FWSFW
S
AWS
Take a second piece of 3/32” Rod 8” long and bend it as AWS4”
4” 4”
2”
4”
2”
STEP # 31
Insert FWS into Holes A & B and AWS into Holes C & D.Cut TWO (2) WCB (Page 34) from corrugated cardboardand tape them to FWS and AWS as shown below.
FWSFWS
AWSAWS
WCBWCB
AB
CD
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STEP # 32
Splicing Two Cans Together.
(1) Tape One Can to a piece of glass or to thesurface of a smooth table. (2) Apply a strip ofDOUBLE-SIDED Tape on the edge of the Can.(3) Stick the Second Can on Top of the double-sided tape and tape it to the Glass/Table. (4)Tape the Two Cans together with a strip of ClearCellophane Tape on BOTH the Top and Bottomsides of the Cans.
(1)
(1)
(2)
(2)
(4)
(3)
(3)
(4)
CanCellophane TapeDouble-Sided Tape
STEP # 33
Take Double-Sided Tapeand apply four (4) stripps to theUNDERSIDE of WCB as shown atthe right.
Stick the Cans, from Step # 32,onto the UNDERSIDE of the wingand trim as shown here.
WCB
STEP # 34Cut a piece of cardboard to roughly the shape of WCBAFshown at the Left. Using Double Sided Tape, stick it to theleading edge of the wing (WCB).
Take Double-Sided Tape and apply astrip to the TOP SIDE of WCBAF.
WCBAF
WCB
Cover Top of Wing with Cans.
When you trim the TopCan leave enough extraCan to wrap OVER theLeading edge of theWing. Trim Wing Edge
leaving an extra1/4” to coverWing Tip joints.
STEP # 35
STEP # 36
Cut TWO HS (Page 32) from corrugated cardboardand cover with Cans as shown at the Right.
HS
HSHS HS
“Flip” Template to get Right and Left HS.
Cover Top With Canand glue in place.
Cover Bottom with Can
Wrap Bottom Can around Edges
BottomView
STEP # 37Splice THREE Cans together as you did Two Cans backin Step # 32 and cut TWO EIC’s (Page 35) from them.
Flip Template to get Right and Left EIC’s
STEP # 38
Take the Right EIC and place the FORWARD LOWERTAB # 1 into a slit you make in B-4 just forward of the FWS.
Epoxy the EIC in placeagainst B-4 and the Wing.
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Roll EIC around a broomhandle to get shape.
STEP # 39Bring the EIC acrossthe wing and mark theBack of B-2 whereyou’ll make your slit forTab # 2.
Insert Tab # 2 into theslit you make for it andepoxy the Back end ofEIC to B-2.
Trim EIC to fit theTop contour of the wing.
EICEIC
STEP # 40
Bring the EIC into place against B-1, B-2 & B-4 and mark whereyou’ll make the slits for Tabs 3, 4, 5, 6, & 7.
Insert the Tabs into the slits and hold EIC in place with tape.Working through the Inlet and Exhaust ofthe EIC, epoxy the EIC in place on theINSIDE.
STEP # 41
Repeat Step # 40 on the Left EIC.
STEP # 42
Take TWO Bottle Caps and spray paint them Flat Black.Epoxy the Caps into the Exhaust end of the EIC’s.
STEP # 43
Cut TWO (2) AB’s (Page 34) from a Can and form into a cone. Matchup A with A and B with B. The Tab goes on the INSIDE.
AB
AB AB
AB
ABAB AB
AA
BB
Epoxy into place in the AFT End of the EIC.
STEP # 44
Cut TWO WT’s (Page 30) from Card-board and cover with Cans as you did tothe HS in Step # 23.
WT WT
WT
WT
WT
STEP # 45Epoxy a piece of 3/32” Rod 1/2” long into theWT as shown at the left and epoxy the WT tothe Wing’s Edge. Trim any excess Can to get asmooth fit.
Wing Tips have a 15° Up-Sweep.Use Tape to hold in place until WT is secure.
WT
REPEAT ON OTHER WING.
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STEP # 46Make a 3/32” Hole on BOTH SIDES of theTC, 1 1/2” from the end and 1/4” either sideof Top Center.At the same time make a 3/32” Hole TopCenter 1 3/4” from the end of TC, andanother 3/32”, also Top Center, 3” from theend of TC as shown.Insert a piece of 3/32” Rod 2 1/2” long, bentat 45° into the HS Holes as shown below.
1 1/2”
1/4”
TC
TC1 3/4”
3”
STEP # 47
Insert the HS’s you made in Step # 36 onto the Rodand epoxy in place.
HS
STEP # 48
Cut ONE VS (Template #8, Page 30) from cardboard andcover with Cans as you did with the HS and WT.
Epoxy a piece of 3/32” Rod into both of the holes youmade on the Top of TC and insert and epoxy the VSinto place.
VS
STEP # 49
Your plane should now resemble this >
STEP # 50
Cut GC (Page 34) from a Can and epoxy itUNDER B-4, B-5 & NC as shown here.Use Tape to hold it in place until secure.
GC
GC
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STEP # 51
The Cock-Pit Canopy is made from theshoulder of a plastic bottle. I’ve found the“Equate Baby Shampoo” bottle to have themost favorable shape although you can alsomake the Canopy from any similure bottleor even use a Can. I got the Equate bottleat Wal-Mart.
Trace the FWS & AWS (Page 35) ontothe bottle as shown. You can get TWOCock-Pit Canopies from every bottle.
Once you have the FWS & AWS cut out you can spray paint them ,on the INSIDE, whatever color you like.
STEP # 52
Epoxy the AWS, REAR Tab, into Slit # 1 on B-1.Mark B-4 where the Side Tabs will go and makethe slits for them. Epoxy the AWS in place.
Mark B-4 & B-5 where the slits for the FWS willbe made. Make the slits, insert and epoxy theFWS in place.
AWS FWS
Slit # 1
FWSAWS
STEP # 53
Tape Cock-Pit Canopy as shown here.
Tape edge of EIC as shown here.
STEP # 54
Cut TWO EIR’s (Page 34)from Can and epoxy to theside of B-4 at the opening ofEIC as shown here.
EIR EIR
EIR
Detail with Victory Markings if desired.
STEP # 55
Take a piece of 3/32” Rod 6” long and bend it as shownat the Left. Put a 3/32” hole in the bottom of B-3(where shown) and epoxy the AH in place.
AH
AH If You’ll be displaying your plane without Landing Gear thenyour B. C. Air Originals F-4 Phantom II is now complete.
STEP # 56Take FOUR (4) BottleCaps and put a 3/32”hole in the Center ofEach Cap. (Paint theCaps Black if you like.)Epoxy Two Capstogether to make OneWheel. (Add WheelHubs, Page 35 if youlike.)
STEP # 57
Take TWO pieces of 3/32”Rod 4 1/4” long and bend itas shown at the Left.
1”
1”
1 1/4”
1”
The Aluminum Tubing is Optional.
STEP # 58Make a 3/32” Hole in theUNDERSIDE of the wing 2”from the Wing’s LeadingEdge and 1 3/4” from theWing Tip’s Leading Edge asshown at the Left. Epoxy theMain Landing Gear into theHole as shown at the Right.2”
1 3/4”
STEP # 59
Mount the wheel on the MainLanding Gear. and cut off anyexcess Rod. Epoxy the MainLanding Gear Door MLGD (Page32) in place as shown at the Right.
MAIN LANDING GEAR
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STEP # 60
Cut FOUR (4) 3/4” circles outof cardboard. Glue TWOtogether to make One Wheeland put a 1/16” hole in theCenter. Paint the circles Blackand add the Wheel Hubs(Page 35)
STEP # 61
Take a piece of 1/16”Rod 4” long and bendit as shown in Photo A.Then bend it as shownin Photo B.
A
B
Small piece ofAluminum Tubeis optional.
Make a 1/16” hole in IGCwhere B-4 & B-5 arejoined, and INTO F-3.Epoxy NWLG in place.
NWLG
Mount Nose Wheelsand NWLGD in place.
Nose Wheels go on here.
Your B. C. Air Originals F-4 Phantom II is now complete.
Nose Wheels
Page 34
F-1F-2
F-3
F-4
B-3
B-4
31
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A A
BB
A A
B B
B-5
32
NC
TC
TABTAB
VS
HS
MLGD
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A A
B B
A A
B B
A
A
B
B
.
.
.
.
BOTTOM CENTER LINE
Flus
h w
ith F
RO
NT
of B
-1
A B
A B
Slit # 1
Slit # 1
Hole B
Hole A
Hole D
Hole C
Template # 1
Trace Template # 1 onto a piece of Mylar, cut out and form into a cylinder matching up A with A and B with B.
