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.
36 Pages With Over 125 Full Color Photos
showing how to build the

Piper Cherokee
FROM CANS !

Wingspan: 17”
Length: 14”
Height: 4 1/2” PA-28-140

T
Can be made from most

RE
12 or 16 oz Beverage Cans.
C
SE
TOP www.bcair.com
Copyright © 2013 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 - Piper Cherokee. 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 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 Wings, or the Tail Section 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 10-11 Cans to make.

STEP # 2
cut the Tops and Bottoms off All Cans and
open them up as shown here. (See Page 6)

GET AS MUCH OF THE

CAN AS POSSIBLE

STEP # 1 Pull Tab

Once you’ve selected which Cans you’ll
be using to make your plane out of,
Remove the Pull Tabs from all Cans and
www.bcair.com

STEP # 3

Cut out Template # 1, (CPF) page

<--

CPF 33, from a piece of corrugated card-

Co

board.
rru
gat
ion
Ru
ns-
->
 <--
Co
rru
gat
ion
Ru STEP # 4
ns-
->
Score CPF where indicated.
CPF
CPF

CPF

-->
Run ation
STEP # 5

g
s
orru
Cut TWO pieces of corrugated Cardboard 1 1/2” x 3 3/8”

<--C
and place them both in the bottom of the CPF.
NOTE that the corrugation of these two pieces
runs from Side to Side, NOT Front to Back.

STEP # 6

Bring the sides, front and back of the CPF

up and glue them into place as shown.

(I used my Hot Glue Gun for this.)

CPF

CPF
 <--Corrugation Runs-->
WSF

Template # 2
EM
<--Corrugation Runs-->
Template # 3

STEP # 7 Cut Templates # 2 & 3 (Page 33) from corrugated cardboard as shown.

Note how WSF

fitts onto EM.
WSF

EM
STEP # 8

Glue EM inside
CPF
CPF as shown.
EM
(I used my Hot Glue Gun for this.)

STEP # 9
WSF
Glue WSF onto EM as shown.

EM
WSF

www.bcair.com
EM
 EM
STEP # 10

Cut TWO pieces OF THE FRONT

<--C END of Template # 2 (EM) from
orru
gati corrugated cardboard.
on R
uns
-->

Glue these two pieces to each

side of the EM as shown.

(I used my Hot Glue Gun for this.)

2”
STEP # 11

Take a piece of 3/32” Rod, 5” long, and glue it

into the EM. Leave 2” of the Rod sticking out
as shown.
(I used contact cement for this.)
STEP # 12 Marry Two Cans, from Step # 2, together as shown here.

Glue on INSIDE

Can
Cellophane Tape
Double-Sided Tape

STEP # 13
Template # 4
Cut Template # 4 (TC - page
34) from the Two Cans that you
married together in Step # 12.

Place strips of clear tape on the

INSIDE of the TC and Score
the TC on the INSIDE, where
shown.

(The tape will help to keep the

Cans from cracking and break-
ing apart.)
 www.bcair.com
STEP # 14

Shape the TC and hold it’s shape with

a piece of clear tape on the UNDER
SIDE where the Cans over lap. Glue
on the INSIDE.

(I used contact cement for this.) TC

Template # 5

<-
-C
TCF
or
ru
ga
tio
n Ru
ns
-->

<--Corrugation Runs-->
STEP # 15
Cut out Template # 5 (TCF), page 33, from
corrugated cardboard and put a “thin” beed
of hot glue around the edge. Insert the TCF
into the TC and glue it in place.
TCF
(I used my Hot Glue Gun for this.)

www.bcair.com

TC
Completed Tail Cone
 CPF

CPF

STEP # 16 Glue the TC on to the back end of the CPF.

(I used Hot Glue to do this.)

STEP # 17

Use your BLACK Sharpie and blacken the front of the EM.

WSF

CPF
EM
 STEP # 18
A B C Take any clear 1
liter plastic bottle
and remove the
label (A). Mark
the bottle as
shown (B). Cut
the bottom of the
bottle off (C), then
cut up the side of
the bottle (D) and
cut the top off (E).

D E

STEP # 20
Paint the INSIDE of the WS black.
STEP # 19
Trace Template # 6, page 36, onto the plastic
bottle as shown and cut out the WS.

Template # 6 WS
WS
 Trim EM if necessary.

EM

EM

WS SLIT WS SLIT
CPF

STEP # 21 Place WS in position (on the CPF) and mark the

CPF where slits will be needed for the WS Tabs.

STEP # 22 Glue WS in place on top of EM and CPF as shown.

(I used Hot Glue for this.)

WS

www.bcair.com

STEP # 23

Trace Template # 7, CPC (page 35),

onto a Can and cut out the windows
CPC as shown.
FIRST, “SCORE” the windows with a
ball point pen.
NEXT, cut a small hole in the middle of
the window, using your X-Acto knife.
NEXT, use a small scissors and cut,
from the hole, to each corner of the
window. (See next page).
STEP # 24 (CONT)

(Cut, from the hole, to

each corner of the
window.)

Now “bend INWARD”

each piece of window
Can and it should break
off cleanly.

Repeat Step 23 for

each window.

Cut out the remainder

of the CPC.
 STEP # 25

Glue CPC in place

WS onto the WS, TC and
TC CPF as shown.

EM (I used Hot Glue and 2-

Part Epoxy for this.)
CPC
www.bcair.com

STEP # 26
Cut out Template # 8, WS
EC (page 35), and glue
it into it’s shape as you
did with the TC. EC
Glue the EC onto the
CPC and WS as
shown. (I used Hot
Glue on the INSIDE for
this.) CPC
 STEP # 27
Take seven (7) Pull Tabs and glue them into a
stack. Use a strip of tape to hold them in place
until the glue is dry. Make Two (2) stacks.
These will be the Engine Cylinders.

Glue on the INSIDE

(I used contact cement (E6000) to do this.)

STEP # 28
Glue one Engine
Cylinder to either side
of the EM as shown.

(I used 2-Part Epoxy

for this.)

EM
 STEP # 29

Trace Template # 9, (page 34), FEC,

onto the INSIDE of a Can bottom and
cut it out. (SEE NEXT PAGE)

Glue the FEC onto the front of the EC.

Trim the front of the EC to get a tight fit.
FEC
(I used 2-Part Epoxy to do this.)

EC
FEC
EC

FEC

www.bcair.com
EC
EC

FEC FEC
 This is how I do it.
2
1
After tracing the
FEC onto the
INSIDE bottom of a
Can bottom that
I’ve cut off, (page
6), I “slowly” cut
away the Can.
I’ve taken an ordinary scissors
and rounded off the ends.

3 The trick is not to

try and cut the
thing out in one 4
pass. Just cut a
little at a time.

Then trim as
needed.

Once you have

6
5 the outside
dimension, put a
hole in the
center. I just use
my awl (sharp-
ened screw-
driver) or you
could “drill” a
hole also.
Next I use a small manicure scissors
Again, don’t try and do it all in and “gently” cut out the center.
one pass. Cut a little out at a time.

7
Once I have it
pretty much 8
the way I
want it, I use
a “rat-tail-
file” to
smooth out
the edges.
 1/4”
STEP # 30
WCBAF
Cut Two Template # 10,
WCB, and Two Template Top Left Wing
# 11, (page 36), WCBAF,
from corrugated card-
WCB
board. <--Corrugation Runs-->
1/4”
Glue/Stick the WCBAF
onto the Top of the WCBAF
WCB, 1/4” back from the
leading edge.

(I used double face tape

Top Right Wing
WCB
to do this.)

DO NOT PUT ANY This is where the Landing

GLUE IN THIS AREA. Gear will attach.

Bottom View Right Wing

STEP # 31

Cover the Bottom of the

WCB with a Can and trim
to shape as shown.

WCBAF (I used double face

tape to do this.)

WCB Leave 1/4” overlap in

the Bottom Can.

Top View Left Wing

STEP # 32

Put some glue on the top

of the WCBAF and cover
the top of the wing with a
Can.

(I used double face

tape to do this.)

Trim Top Can to

shape and fold over
the edges as shown.

www.bcair.com
 CPC

STEP # 33 Make Wing Spar Holes in CPC as shown (BOTH SIDES).

CPC
1 1/2” 1 1/2”

These holes should go through the Top and the Bottom pieces of cardboard in Step # 5

STEP # 34
Take TWO pieces of 3/32” Insert the Two Wing Spar
rod, 10” long, and bend as Rods through the holes
shown. you made in Step 32 and
3/4” glue them in place.
5” 5”
(I used 2-Part Epoxy for
this.)
 Be sure
Wing
Spars are
parallel
with each
other.

STEP # 35

Put some glue/epoxy

on the wing spars and
on the WCB where
the wing will come in
contact with the
plane’s body and
slide the wings into
place.

(I used 2-Part Epoxy

to do this.)

www.bcair.com

Push wings in place

and hold until Epoxy
is dry.
 STEP # 36

<-Corrugation Runs->
Cut Template # 12, VS, (page 34), and
VS Template # 13, HS, (page 35), from corru-
gated cardboard and cover with Cans as
you did the wings.
<--Corrugation Runs-->
HS STEP # 37

Take Two pieces of 3/32” Rod, 1” long

and glue them into the Base of VS as
shown.

(I used contact cement for this.)

VS
VS

1/2” 1” 3/4”

HS

When you cover the HS with Cans, leave

an opening at one end as shown.

HS

HS
 STEP # 38

Make 3/32” holes in the Tail cone as shown.

VS Holes
1”

3/4”
1”
3/4”

1/2”
1/2”
HS Holes

STEP # 39

Notch HS as shown to fit onto Tail Cone.

www.bcair.com
 VS Holes

HS Hole HS Hole
STEP # 40

Take a piece of 32” Rod

5” long and put some
glue/epoxy on it, then
insert it into the HS as HS
shown.

(I used 2-Part Epoxy for this.) Rod will go through the HS Holes
that you made in the Tail Cone.

Put some glue/

epoxy on the HS
cardboard where
it will meet the Tail
Cone. Push the
Rod all the way
through the HS
holes, (in the Tail
HS
Cone), and hold
the Tail Cone in
place until the
glue/epoxy is dry.

Finish folding over

the edge of the
Top Can of the
HS.

HS
 STEP # 41

Put some glue/epoxy

on the Rods in the
VS (Step # 36) and
on the base of the VS
cardboard. Insert the
rods into the VS
holes, in the Tail
Cone, and hold the
VS in place until
VS
secure.

(I used 2-Part Epoxy

for this.)
HS

Make sure the VS is at a right angle to the HS.

VS

HS
 STEP # 42 (OPTIONAL)

Glue a small Flat Headed Nail into the www.bcair.com

Top of the VS and into each of the
Wing Tips as shown. (Push the nail all
the way in.)
(I used contact cement for this.)

Use a magic marker, or paint, the

Right Wing Tip Nail GREEN, the
Left Wing Tip Nail RED and the VS
Nail WHITE.

Put a small “bubble” of Hot Glue on VS Light

each Nail Head.

(These are the planes navigation

lights.)

Right Wing
Nav Light

Left Wing
Nav Light
 1 1/2”

5”
(2 1/2” either side of center line)

STEP # 43

Make 3/32” holes in the

Underside of the wings as
shown for the Main Landing
Gear. Holes should go
through the bottom Can and
INTO the WCB.
1 1/4” EC
Make a 3/32” hole in the
Bottom of the EC as shown.
Hole should go through the
Can and INTO the cardboard
EM.
 STEP # 44 Wheels Here are Two options for your Wheels.

(1) Take Six Bottle Caps and put a

3/32” hole in the center of each cap.
Glue/epoxy 2 Caps together to make
One Wheel. Paint the Wheels Black.
(I use 2-Part Epoxy for this.)

(2) You can also use Rubber Model Plane Wheels like these.
On this plane I used “Sullivan Tailwheels”
from Tower Hobbies.
1” Stock # LXFU87 for the Main Gear
3/4” Stock # LXFU86 for Nose Gear

www.bcair.com

STEP # 45 Landing Gear

Take 2 pieces of 3/32” rod 2 3/4” long and bend as shown for the Main Wheels Landing
Gear (MWLG).
Take 1 pieces of 3/32” rod 3 1/2” long and bend it as shown for the Nose Wheel Land-
ing Gear (NWLG).
OPTIONAL: Use 1/2” pieces of 3/32” Tubing as shock absorbers.

NWLG
MWLG

1/2”
1/2” 1/2”
1/2” 1 3/4” 1/2”

1” 1/2”
1/2” 1”

1/2”

3/4” 3/4”
3/4”
 STEP # 46
Insert MWLG into the holes in the bottom of the wings and
work them “through” the WCB into place. Glue in place.

123
Wheel123
123 12345678901234567890
123 12345678901234567890
123
MWLG 12345678901234567890
123 12345678901234567890
Wheel 123
123 12345678901234567890
123 MWLG
12345678901234567890
123
12345678901234567890
123
Bottom Can 12345678901234567890
123
12345678901234 12345678901234567890
123
12345678901234 12345678901234567890
WCB
12345678901234
WCB 12345678901234567890
Top Can

STEP # 47
Secure Wheels onto the Landing Gear.
Insert NWLG into the hole in the bottom of
EC and “INTO” the EM. Glue in place.
 STEP # 48
Install prop onto PS and secure in place with a nut.
Cut off excess PS. Add a POINTED “GOB” of
Hot Glue to the front of the prop and paint it Black.

On this plane I used a prop from Tower Hobbies (www.towerhobbies.com). Prop # LXZ947

STEP # 49 Outline Cabin Door with black marking pen.

Your B. C. Air Originals Piper Cherokee is now complete.

STEP # 50 Show ALL your friends your completed plane !

 Templates # 3

WSF

1 7/8”

Blue Lines are

Score Lines

Template # 1

CPF
3 1/2” Template # 5

TCF

1 3/4”
www.bcair.com

Templates # 2

EM

33
 Template # 9

FEC
TAB

www.bcair.com

Template # 4

7 3/8” TC
Blue Lines are Score Lines

OVER TAB

Template # 12

VS
34
 Leading Edge

Template # 13

HS

www.bcair.com
TAB

Blue Lines are Score Lines

TAB

Top Center Template # 8

8 1/4” Engine Cowling

EC

Template # 7

CPC

OVER TAB

OVER TAB

35
 Template # 11 WCBAF

3”
Template # 10

WCB
Flip to get Left and Right Wing.
A

www.bcair.com
B

WS
Windshield
Template # 6
Match up A with B

36