B.C. Air Republic P-47D Thunderbolt User manual

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

www.bcair.com
Copyright © 2013 B. C. Air Originals
Step By Step Construction Plans.
37 Pages With Over 170 Full Color Photos
showing how to build the
Can be made from most
12 or 16 oz Beverage Cans.
Wingspan: 16”
Length: 14”
Height: 5”
TOP SECRET
Republic P-47D
Thunderbolt

Welcome to the B. C. Air Originals Squadron.
This booklet contains complete step by step instructions for building the B. C. Air
Originals - Republic P-47D Thunderbolt. Before you start building your first
plane it is suggested 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 [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 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://
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”)

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.
SEE ALL THE BUILDERS TIPS ON-LINE AT > www.bcair.com/BT
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.
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!
In ALL cases, cut
the Bottom off the
Can FIRST, then
cut the Top off.
Get as much of the
Can 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 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”
SEE ALL THE BUILDERS TIPS ON-LINE AT > www.bcair.com/BT
(This is the method I used to make this plane.)
6

Once you’ve selected which
Cans you’ll be using to make
your plane out of, take one
Can and designate it as B-1.
Remove the Pull Tab and
make a 1/4” hole in the center
of the bottom of the Can.
STEP # 1
This Plane takes a total
of 13 Cans to make.
B-1
Pull Tab Next make 6 - 3/32” holes along the bottom rim
of the Can as shown.
STEP # 2
Wrap Template # 1
(page 34) around B-1
and make Holes A&
B.
OPTIONAL:
Make Holes C& D
ONLY if your plane
will have the Belly
Fuel Tank (Step 47).
Make the slits for the
Cockpit opening.
Template MUST be flush
with Front of Can.
www.bcair.com

STEP # 3
STEP # 4
B-1
Remove Template # 1
from B-1 and trim the
Pilot’s seat as shown.
Bend Half of the Seat
straight Up and then
bend the other Half of
the Seat Down Into the
Can.
Use your Can Opener and
cut out the FRONT of B-1.
STEP # 5
Using your fingers, Two inside at the Top and
One inside at the Bottom, PULL the Can Rim
into the shape shown.
B-1
B-1
..
Pilot’s Seat

STEP # 6
STEP # 7
www.bcair.com
Strip approx 3” of rubber insulation off a
piece of 10 gage electrical wire and cut the
outside edge as shown. Then cut it in half
and glue it on the cockpit edges as shown.
Glue the IP to the INSIDE of B-1
Print out the
Instrument Panel
(page 35) onto
Card Stock, cut it
out and glue it in
place inside the
Cockpit.
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Can
Cellophane Tape
Double-Sided Tape
Glue on INSIDE
Cut the Tops and Bottoms off 10 Cans and
open them up as shown here. (See Page 6)
STEP # 9
STEP # 8
GET AS MUCH OF THE
CAN AS POSSIBLE
Marry Two Cans, from Step # 8, together as shown here.
STEP # 10
Cut Template # 2 (B-2 - page 36) from the Two Cans
that you married together in Step # 9 and form it into a
cone. Hold it’s shape with a piece of tape on the
OUTSIDE and glue on the INSIDE as shown.
B-2
TAB goes on the INSIDE

1 1/2”
The Overlap of the Cans, on B-2, should
be on the BOTTOM of the Plane.
STEP # 11
Top View Side View
Glue B-2 onto the Back End of B-1.
Trim where necessary to get a tight fit.
The holes in the back rim of B-1 will
give the glue something to anchor to.
DO NOT PLUG THE HOLE IN THE
CENTER BACK END OF B-1.
B-1 B-1
B-2 B-2
Side View
Put some glue around the INSIDE rim of B-2.
www.bcair.com

www.bcair.com
STEP # 13
Take another Can and
wrap the TOP end of
it with a piece of paper
2” wide as shown.
Mark the Can all the
way around.
Use your Can Opener
and cut the Front of
the Can out.
STEP # 12
Use your X-Acto knife and rough cut the Bottom of
the Can off.
Then use
your
scissors
and clean
cut the
Front of
the Can
off.
STEP # 14
Using your fingers, (as
you did in Step # 5)
Two inside at the Top
and One inside at the
Bottom, PULL the Can
Rim into the shape
shown.
This will be B-3.
B-3

STEP # 15
B-3 B-1 B-2
Glue B-3 to the Front end of B-1 as shown.
STEP # 16
Take Two pieces of 3/32” Rod,
7” long, and bend them as shown
below. These will be the Wing
Spars (FWS & AWS).
Enlarge holes A& B, in B-1, to
3/32” and insert the Rods through
them as shown.
When you have the Rods even
and parallel with each other, glue
the Rods to the INSIDE of B-1.
1”
3 1/2”
3 1/2”
A
B
B
A
FWS
AW S
AW S
FWS
B-1

STEP # 17
WCB
WCBAF
<--Corrugation Runs-->
Cut TWO WCB & TWO
WCBAF (Templates # 3 & 4 -
page 37) and glue the WCBAF
(1/4” back from the leading edge)
on Top of the WCB as shown.
STEP # 18
Cover the Top of the Wing with a Can.
Note that the Can covers the WCBAF
but does not cover the leading edge of
the wing.
Underside view of the wing.
Make notches in the Can to bend
around the trailing edge of the wing.
www.bcair.com

www.bcair.com
STEP # 19
Cover the Underside of the wing by gluing
a Can to it cut to the same shape.
STEP # 20
Note that the Bottom Can extends 1/4”
beyond the WCB where the wing will
meet B-1.
Take a piece of Can 1” wide by
8” long and fold it around the
leading edge of the wing as
shown. Note that the INSIDE of
the Can is on the OUTSIDE of
the fold.
Glue the Leading Edge piece of
Can to the leading edge of the
wing and fold over the wing tip as
shown.
Mark each wing as shown at the
right. DO NOT put any glue in
the 7/8” area shown. That is
where the wing guns will go.
2 5/8”
7/8”
No Glue here.
Glue Glue

STEP # 21
7/8”
1/4” 1/4” 1/4”
Make 4 (Four) 1/16” holes in the leading edge
of each wing, in the 7/8” area, as shown.
Take 4 (Four) pieces of 1/16” tubing, 3/4”
long (you could also use 3/32” Rod pieces, or
whatever else you have handy) and glue them
into the holes as show.
1/16” Tubing
3/4” long
1/8”
1/4”
3/8”
1/2”
From the Leading Edge of the Wing.
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STEP # 23
STEP # 22
Put some 5 minute Epoxy onto the
WS’s and slide the Wings onto the
WS’s and push them up tight against
B-1 until epoxy is dry.
Place the finished wings into position,
over the WS’s, and mark the lower Can
where the WS’s will insert into the Wing.
The leading edge of the wing is 1/2”
Forward of the Back End of B-3.
1/2”
B-3 B-1
FWS
FWS
AW S
Your plane should now
look something like this.

www.bcair.com
STEP # 25
STEP # 24
Make Four (4) 3/32” holes in the
Tain Cone where the HS Rods will
insert.
1 1/4” from end of Tail Cone
and 3/8” either side of center.
1/4” from end of Tail Cone and
1/8” either side of center.
Cut out TWO (2)
HS (Template # 5
- Page 37) and
cover with Cans
as shown.
HS HS
HS
(Left HS- Top View)
(Left HS- Bottom View)
(Completed Left HS- Top View)
(Left HS- Bottom View)
Glue Can on the
Bottom of HS.
Glue oversize Can
on the Top of HS.
<--Corrugation Runs-->
Cut notches in Can
and fold Can
around edges.
1 1/4”
1/4”

STEP # 28
STEP # 26
STEP # 27
Insert Two 3/32” Rods, 2”
long, through the holes that
you made in the Tail Cone.
(Bend the Rods as needed.)
Mark the HS’s where the
Rods will insert.
Put some Epoxy/Glue on the
Rods and slide the HS’s onto
them.
Hold HS’s in place until
Epoxy/Glue is dry.
Make a 3/32” Hole in the Top
Center of the Tail Cone, 3/4”
from the Back of the Tail Cone.
Cut VS (Template # 6 - Page 36)
from corrugated cardboard.
VS
<--Corrugation Runs-->
3/4”