Wayne - B.C.AirOriginals Grumman F4F Wildcat. Before you start building your first plane it is suggested that you review the entire set of plan directions. Once you have pre-viewed

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

amount you donate is greatly appreciated.

May God bless you and keep you safe.

Thank You & Enjoy!Wayne

www.bcair.comCopyright © 2012 B. C. Air Originals

Step By Step Construction Plans.44 Pages With Over 150 Full Color Photos showing how to build the

Can be made from most12 or 16 oz Beverage Cans.

Wingspan: 16”Length: 12”Height: 5”

TOP SECRET

Grumman F4FWildcat

Welcome to the B. C. Air Originals Squadron.

This booklet contains complete step by step instructions for building the B. C. AirOriginals Grumman F4F Wildcat. Before you start building your first plane it issuggested 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 touse to make your first plane. These plans are designed to be used with most any 12or 16 oz. beverage can. Always use clean, unscratched and undented cans for thebest 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 Engine, the Wheels or the Tail Section first, you can do thatand then set them aside until you need them. However, until you understand theconstruction 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 aredrawn to scale. Using a sheet of mylar (Clear Plastic) will enable you to re-useyour templates again and again. There is no limit to the number of planes you canbuild 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.

http://www3.towerhobbies.com/cgi-bin/wti0097p?FVSEARCH=PROPELLERS+++&CATEGORY=QB&MANUFACTURER=TOP&submit=Submit+AdvancedSearch

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.X-acto knife (hobby knife) (box opener).Scissors & Can Opener.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).

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 Bottomsof the 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 possable.

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

(This is the method I used to make this plane.)

6

STEP # 2

B-1

Once you’ve selected which Cans you’ll beusing to make your plane out of, cut the Topsand Bottoms off 11 Cans and open them upas shown here. (See Page 6)

STEP # 3

Next, remove the PullTab from B-1 and puta 3/32” hole in thecenter of the littlebutton where the PullTab was.

STEP # 4Now turn Can B-1 over and put a 3/32”hole in the center of the bottom of theCan.

B-1

Take another Can and designate it as Can B-1.

STEP # 1

This Plane takes a totalof 13 Cans to make.

B-1

Also make 4 to 6 3/32” holes around thebottom of the Can as shown. (These willgive the glue [Step 17] something to anchoronto.)

STEP # 6 - OPTIONAL

STEP # 5

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Cut out Template # 1 (Page 41) and wrap itaround Can B-1. Hold in place with a pieceof tape.

Twist Template #1 around the Can until youhave the “Center Bottom of Plane line”where you want it.

The TOP of Template # 1 should be flushwith the FRONT (TOP) of Can B-1.

Use your Push Pins and make holes A & B.

LANDING GEAR HOLES :

If you’re going to display your plane with thelanding gear UP, make the RED holes withinthe two circles ONLY.

WING STRUT HOLES :Bottom of Can

Bottom of Can

Remove the Push Pins from the RED holesand enlarge these two RED holes to 1/4”.(This will give the glue [Step 60] somethingto anchor onto.)

Leaving the Push Puns in place, use yourX-Acto knife and make the three (3) slitsfor the Cockpit.

STEP # 6 - OPTIONAL

LANDING GEAR HOLES :

If you’re going to display your planewith the landing gear DOWN, make theRED, BLUE, and GREEN holes withinthe two circles.

STEP # 7

COCKPIT OPENING :

Top of Can

Bottom of Can

Bottom of Can

Remove the Push Pins and Template # 1from Can B-1.

DO NOT ENLARGE ANY HOLES ATTHIS TIME.

Bend HALF of the “Pilot’s Seat” (that’sthe three slits that you made for the cock-pit) straight up as shown. (Trim the seat.)

STEP # 8

Push (bend) the BACK HALF of the pilot’sseat down into the Can.

. .Pilot’s Seat

B-1

B-1

STEP # 9

Cut out the Instrument Panel(Template # 2- Page 44) asshown.

Fold the Black Tabacross the back.

Glue the round part of theBlack Tab onto the backside of the InstrumentPanel.

Fold the rectangular part ofthe Black Tab as shown.

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STEP # 10

Next manipulate the Instrument panelthrough the cockpit opening and downinto place.

Working through the Drink Hole in the frontof B-1, use a piece of rod and manipulate theinstrument panel into the position that youwant. Then glue the sides of the instrumentpanel to the INSIDE of the Can.

The Top of the instrument panel restson Top of the Can as shown.Glue in place.

STEP # 11

Take a strip of plastic or rubberinsulation from some 10 gageelectrical wire and cut the outsideedge as shown. Then secure itto each side of the cockpit edgesas shown.

STEP # 13

STEP # 12 (Making the Joy Stick)

Take One #4-#6 Stud, 16-14 AWG, Ringelectrical terminal (ET) and remove the plasticinsulator (A).

Take a piece of 3/32” Rod, 1” long, and gluethe ET onto one end of it (B). Take a piece ofrubber insulation and tip the other end of theRod as shown (C). ET

(A) (B) (C)

Take a piece of 3/32” Rod, 9” long, andput a loop at one end of it as shown.This will become the Prop Shaft (PS).

Insert the PS into the BACK END of B-1.Insert the Joy Stick onto the PS and continueto insert the PS through the hole in the buttonin the Front of B-1.

B-1

B-1

B-1

Glue the PS to the Back End of B-1.

Glue the Joy Stick to the PS.

CanCellophane TapeDouble-Sided Tape

8 1/8”

STEP # 14

Marry Two (2) Cans (from Step # 1)together as shown here.

Glue on INSIDE

B-2

B-2STEP # 15

USE AS MUCHOF THE CANSAS POSSABLE

Trace Template # 3, (Page 44),onto these Cans.

STEP # 17

Once the glue in the tail cone (B-2) is dry, Glue B-2 onto the BACK END ofB-1. (The holes that you put in the back of B-1 [Step 4] will give the gluesomething to anchor onto.)Trim where needed to get a tight fit.

Overlap in the Cans is on theTOP SIDE of the plane.

Note the angle of B-2in relation to B-1.

B-2

B-2 B-1

Shape and roll these two Cans until you have asmooth transition into a cone as shown.

Put a strip of clear tape on the OUTSIDE tohold it’s shape and glue the Cans together onthe INSIDE as shown.

STEP # 16

1”

Insert the AWS Rodthrough Holes “B”.

B-1

B-2

When the AWS is in place, glue it to the INSIDE of B-1(work through the drink hole in the front of the Can).

PS

1 1/2”

Take One piece of 3/32” Rod, 10” long, and bend it, in the center, as AWS above.

AWS

STEP # 18 - AFT WING SPAR.

AWS

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STEP # 19 - Wing

Cut Left and Right Wing,Template # 4, out ofcorrugated cardboard.(Flip the Template to getLeft & Right Wing.)

<--- Corrugation Runs --->

<--- Corrugation Runs --->Cut Left and Right WingAirfoil (WAF), Template# 5, out of corrugatedcardboard,(Flip the Template to getLeft & Right Wing Airfoil)and glue them to the TOPof each wing 3/8” Backfrom the Leading Edge.

STEP # 20

STEP # 21

Glue a Can (from Step #1) tothe UNDERSIDE of the wingas shown.

STEP # 22

Trim the Bottom Can to theshape of the wing.Leave 3/8” overlap where thewing will meet the plane bodyB-1.

WCB

WCB

WAF

WAF

WAF

WCB

WCB

STEP # 23

Put a strip of double face tape onthe Wing Airfoil and stick a Canto the TOP SIDE of the wing asshown.

STEP # 24

Trim the TOP Can to the shape ofthe wing, leaving 3/8” extra Can allthe way around to wrap around thewing edges.

Make notches in Can tofold around the wing tips.

UNDER SIDE OF THE WING

UNDER SIDE OF THE WING

TOP SIDE OF THE WINGFinished Left Wing.

Repeat Steps 19 through25 for the Right Wing.

STEP # 25

STEP # 26

STEP # 27

Take 4 Electrical Terminals (ET) andremove the plastic insulators.(These will be the wing guns.)

Make slits in the leading edge of the wings as shown and glue the ET’s in place.

1 3/4”1 1/4”

STEP # 28

Insert thewing ontothe AWS.

Leadingedge ofwingshould be1/4” behindwhere theCan beginsto taperinward.

Mark the INSIDE of the wing where the wing sparswill insert into the wing cardboard (See Step # 29).

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STEP # 29Mark the INSIDE ofthe wing where the wingspars will insert into thewing cardboard.

STEP # 30

Take a piece of 3/32”Rod, 6” long, and glue4” of it into the wing asshown. This is theFORWARD WINGSPAR (FWS). FWS

2”AWS will insert into here.

STEP # 31

AWS

FWS

Insert the wing onto the AWSand insert the FWS into B-1.Put some glue on the insideof the wing and secure it upagainst B-1.

STEP # 32

Your plane should now look like this.

Working through the drink hole inthe front of the Can, glue theFWS to the PS.

.

B-1

STEP # 33

Cut out Template # 6, VS, from corru-gated cardboard and cover with piecesof Can in the same way that you did thewings.

VS Left Side

VS Right Side

<---

Cor

ruga

tion

Run

s ---

>

VS

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STEP # 34

Cut out TWO HS, Template# 7, and cover with piecesof Cans in the same way thatyou did the wings and theHS.

HS HS

HS Under Side

HS Top Side

STEP # 35

STEP # 36

STEP # 37

Take Two pieces of 3/32” Rod andglue them into the VS as shown.

2 1/2” 1 1/2”

Make corresponding holes in the TailCone and glue VS into place.

VS

VS

Take a piece of 3/32” Rod 3” longand bend it asshown. Make ahole in the Bottomof the Tail Coneand glue the TailWheel in place.

2”

STEP # 38

Fill the hole in theback of the TailCone with hot glue.

Use a piece of Canto flair the TailWheel.

STEP # 39

Take Two pieces of3/32” Rod andinsert them throughthe VS. Put someglue on them andslide the HS ontothem as shown.

Forward Rodis 1” long.

Aft Rod is 3” long.

Push HS tightagainst VS untilglue is dry.

STEP # 40

Marry Two Cans together, as youdid in Step # 14, and cut out Tem-plate # 8 (BB) from them.

BB

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STEP # 41

Make slits in B-1 & B-2 where needed for theTabs and glue Tem-plate # 8 into place.

The Front of the BBshould be even withthe Back of the Pilot’sSeat.

B-2

BB

B-1

STEP # 42

Use a Can Pull Tab as theBack of the Pilot Seat and glueit in place as shown.

STEP # 43

STEP # 44

Take a plasticbottle similar to theone shown andremove all thelabels from it.Trace Template #9, (Canopy - C)onto both sides ofthe bottle’s shoul-der and cut theCanopies out.

Make slits in B-1 where needed for theCanopy Tabs and glue the Canopy in place.

STEP # 45

Tape off the Canopy as shown.

Trim Canopyto final desiredshape.

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STEP # 46 - Landing Gear - DOWN

If you’re going to display your plane withit’s Landing Gear UP, go to Step # 53.

2 1/4”

3” 3”

4 1/4”

Take a piece of 3/32” Rod, 8 1/4”long, and bend it as shown here.

Enlarge the GREEN holes in B-1 to 3/32” andinsert the Main Landing Gear Rod through them.

.. .

.

B-1

STEP # 47 - Landing Gear - DOWN - (Continued)

STEP # 48 - Landing Gear - DOWN - (Continued)

1 1/4”

1/2”

1 1/4”

1 1/8” Tubing OPTIONAL.

4”

Continue to bend landing gear as shown.

Continue to bend landing gear as shown.

1/2”

3/4”

The Tubing is 5/32 x .014 Alum Rnd Tube, Stock # 103. Got it at my local Ace Hardwarestore. It’s used just to fatten up the “appearance” of the landing gear at that point. The Landinggear is bent at 1 1/4" but the Tubing is cut at only 1 1/8" (to allow for the bends in the LG).

STEP # 49 - Landing Gear - DOWN - (Continued)

STEP # 50 - Landing Gear - DOWN - (Continued)

Working through the drink hole, glue the main landing gear to the INSIDE of the Can.

Take another piece of 3/32” Rod,4” long, and bend it as shown here.

2”

1” 1”

2 3/4”

Enlarge the RED holes in B-1 to 3/32”and insert this Rod through them. .

. .

.

Take 2 Electrical Terminals(ET) and remove the plasticinsulators.

Slide them onto the MainLanding Gear as shown andglue them to the ends of thisRod as shown.

Working through the drink hole, glue this Rod to the INSIDE of the Can.

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STEP # 51 - Landing Gear - DOWN - (Continued)

.. .

.

Take TWO pieces of 1/16” Rod, 5”long, and bend them as shown. 1 1/4”

1 7/8” 1 7/8”

3 1/2”

Enlarge the BLUE holesin B-1 to 1/16” and insertthese Rods through them.

Take 2 Electrical Terminals(ET) and remove the plasticinsulators.

Slide them onto the MainLanding Gear as shown andglue them to the ends ofthese Rods as shown.

Working through the drink hole, glue these Rods to the INSIDE of the Can.

STEP # 52 - Wheels

View of finished Landing Gear from the underside of the plane.

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Take FOUR Bottle caps and puta 3/32” hole in the center of eachcap.

Use a black magic marker orspray paint the caps black. Glue/epoxy TWO caps together tomake one wheel.

Glue the wheel hubs onto thesides of the caps.

Install the wheels onto the MainLanding Gear, cut off excessRod, and hold wheels in placewith a spot of glue.

Stack 6 or 7 Pull Tabs, hold in place witha strip of tape, and glue/epoxy themtogether. Make 7 stacks of Tabs.These will become the Engine Cylinders (ECS).

Take 4 bottle caps and puta 3/32” hole in the center ofeach cap. Glue/epoxy 2caps together as shown.

.

.

.

Glue/epoxy the 4 bottlecaps together as shownhere.

Wrap the caps 5-6times with duct tape.

This willbecomethe EngineCrankCase(ECC).

Place the ECS around the ECC andglue/epoxy in place. Use a rubberband to hold them in place until theglue/epoxyhas dried.

FRONT VIEW

Be sure toremove alltape fromECS beforegluing themaround theECC.

STEP # 53 - Engine

* OPTIONAL *Glue 3/32” Rods,or small nails,around the engineto represent ValvePush Rods.

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* OPTIONAL METHOD FORADDING VALVE PUSH RODS *

Glue bottle cap, with 3/32” Holein the center, over face of engineto finish off push rods.

3/32” or 1/16” Rod - 1 1/4” long

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STEP # 54

STEP # 55Engine Cowling

Slide the completed engine onto thePS and glue it to the front of B-1.

PS

B-1

Take another Can and wrap itwith Template # 10 as shown.

Mark the Can all the way around.

Use Push Pins and make the TwoExhaust Holes where shown.

BOTTOM OF CAN

STEP # 56Engine Cowling - Continued

Rough cut the Bottom off the Can.

Trim Can at the Template edge.

Make Cowl Flap cuts where indicated.

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STEP # 57

STEP # 58

Remove the Push Pins and theEngine Cowl Template and, usingyour Can Opener, cut the FRONTout of the Can.

Slightly bend openthe Engine CowlFlaps.

Put some glue on theINSIDE of the EngineCowling and slide itover the engine and thefront of B-1.

If you use a plastic, or wooden, model airplane prop you may find that the hole in the centerof the prop is larger than the PS. To reduce the size of that hole you can use a 3/32” AnchorBolt glued/epoxied into the back of the prop.

FLATTEN the three spikesbefore securing to the prop.

STEP # 59

Install the Prop onto the PS, cut offexcess PS, and secure in place with anut or wire clip or some other means.

Be sure the Prop will spin freely.

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On this plane I used a prop from Tower Hobbies(www.towerhobbies.com). Prop # LXTEB5

If you’re going to display your plane with it’s landing gear up, take TWO Bottle Caps anduse a Black Marker or Spray Paint them Black.

STEP # 60 - OPTIONAL - (For Landing Gear in the UP Position.)

You do not need to puta hole in the center ofthe Caps.

.

.

.Enlarge the RED hole,in B-1, to 1/4”.

Put some glue on theINSIDE of the BottleCaps and glue them toB-1. (The RED holewill give the glue some-thing to anchor onto.)Glue Wheel Hubs ontothe Caps.

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STEP # 61

Take Two pieces of Tubing 1/2”long and glue them into theExhaust Holes in the EngineCowling.

STEP # 62 - Radio Antenna - OPTIONAL

Take a piece of 3/32” Rod, 3” long, and glue it into BB and B-2 as shown.

Take a small nail, or straight pin, and glue it into VS as shown.

Tie a piece of string between the two as shown.

BB

B-2VS

Gear Up or Gear Down,Your B. C. Air OriginalsGrumman F4F Wildcatis now complete.

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BB

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Plan

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TEM

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1

X

X

Y

Y

www.bcair.com

X to X MUST be 81/4”X to Y should be 5”

When printing out this template.

Cockpit

Cockpit

Center Bottom of Plane

41

.

..

. .

.

.

.

Template # 3

Template # 9

42

CUT

CUT

A

A

B

B

Bring A to B

Bring A to B

TAB Goes on the INSIDE of Cone

B-2

Cockpit Canopy

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TEM

PLAT

E #

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MPL

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# 8

TEMPLATE # 6

WCB

Plan

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Bac

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VS

43

TEM

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4

Tem

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5W

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.

.TEMPLATE # 2Instrument Panel

(Print out on Card Stock)

Wheel Hubs

44

To F

ront

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an

Center Top of Cowl

Cowl Flaps

Cowl Flaps

Cowl Flap

Cowl Flap

Exhaust Hole

Exhaust Hole

X

X

Y

Y

TEM

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10 -

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