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 © 2013 B. C. Air Originals

Step By Step Construction Plans.37 Pages With Over 125 Full Color Photos showing how to build the

Can be made from most12 or 16 oz Beverage Cans.

Wingspan: 16”Length: 5”Height: 4 1/2”

TOP SECRET

Van RV-7FROM CANS !

Welcome to the B. C. Air Originals Squadron.

This booklet contains complete step by step instructions for building the B. C. AirOriginals - Van RV-7. Before you start building your first plane it is suggestedthat you review the entire set of plan directions. Once you have previewed the con-struction steps you should start collecting the cans that you want to use to makeyour 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 lookingplanes.

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 Wings, or the Tail Section first, you can do that and then setthem aside until you need them. However, until you understand the construction ofthese planes, it may be easier to follow the steps in the order listed. Your very firststep should be to make a copy of all the templates. All templates are drawn toscale. 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 withthese 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 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 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. Rat-Tail-FileX-acto knife (hobby knife) (box opener).ScissorsSmall 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 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

Once you’ve selected which Cans you’llbe using to make your plane out of,Remove the Pull Tabs from all Cans and

STEP # 1

This Plane takes a total of 11-12 Cans to make. It is designed to bemade from most 16 oz. beverage Cans but can easily be made fromthe smaller 12 oz. Cans.

Pull Tab

STEP # 2

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cut the Tops and Bottoms off All Cans andopen them up as shown here. (See Page 6)

GET AS MUCH OF THECAN AS POSSIBLE

STEP # 3

Cut out Template # 1,(CPF) page 33, from apiece of corrugatedcardboard.

<--C

orru

gatio

n R

uns-

->

CPF

Score CPF where indicated.

CPS<--Corrugation Runs-->

<--Corrugation Runs-->

Cut TWO (2) CPS, - Page 33 - Template # 2, from corrugatedcardboard and glue them in place onto the CPF as shown.

CPF

CPS

(I used my Hot Glue Gun for this.)

STEP # 4

Note that the Back of CPF sticks upabove the CPS by approx 3/8”.

CPF

CPS

CPS

CPF

CPS

CPF

CPS

CPS

CPS

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STEP # 5

STEP # 6

Cut out Instrument Panel, IP, (Page 37) andglue it to a piece of corrugated cardboard asshown.

Glue IP in place into the cockpit as shown.

Note that the Top of the IP sticksup above the CPS by 1/4”

CPS

CPS

CPF

(I used my Hot Glue Gun for this.Glueing on the Back side if the IP.)

Make 3/32” WS Holes, in CPS, where indicated.

. .

(I used contact cement for this.)

STEP # 7

STEP # 8

Cut out the Seat Bottoms and Backs (Page 37) and glue them to Template # 3 as shown.

1”

1/2”1/2”

1/2”

1/2”

Take a piece of 3/32” Rod, 3” long, and bend it as shown.Tip the ends of the Rod with a 1/4” piece of electrical wireinsulation. (This will be the dual control Joy Sticks.) Gluethe Joy Sticks in place as shown.

(I used Hot Glue for this.)

STEP # 10

STEP # 9

Glue the back of the seat assemblyto the Top Back of the CPF andpush the seats into place within thecockpit as shown.

CPF

Glue on the INSIDE

Top of seat backs flush with Top of CPS.

CPS

CPS

Use a strip of Duct Tape and cover theback of the seat assembly as shown.

CPS

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CanCellophane TapeDouble-Sided Tape

Glue on INSIDE

STEP # 11

NOTE: If you’re using 12 oz. Can to make this plane you will need to marry Two Canstogether as shown below to get the Tail Cone (Template # 4 - Page 30) the correct size.

Cut Tail Cone (TC) Template # 4 - Page 35 from Can/s and shape into a Cone. Hold it’s shape with a strip of clear tapeon the OUTSIDE and glue on the INSIDE (I used contact cement for this). Glue the TC to the Back of CPF asshown (I used 2-Part Epoxy for this). Be sure the TC is flush against the sides of the cockpit.

NOTE:

1 CanPart of a Can

If you are using 12 oz. Cans, to make this plane, you will need to cover the Cockpit (with Cans) in two stages.Cover the back part of the Cockpit first and then the front part. You DO NOT have to marry the Canstogether (as shown on the previous page).

DO NOT enclose the Top of the Forward part of the Cockpit just yet.

If you’re using 16 oz. Cans you should be able to cover the entire Cockpit with one Can using Template # 5,Page 34.

STEP # 12

Glue Can to the Bottom of the Cockpit first.(I used Hot Glue for this)

Then glue the Can to the sides of the Cockpit.

Cut and fold over the edgesof the Can as shown.

DO NOT enclose the Frontpart of the Cockpit just yet.

Cover the Cockpit with Cans.

Trim Cans where needed to get a tight fit.

STEP # 13

Make a 3/32” hole in the lower forwardpart of the CPS (BOTH SIDES) asshown. This will be for the MainLanding Gear.

CPS

STEP # 14

CPS

Make a 3/32” hole in the Back part ofthe TC (BOTH SIDES) as shown.This will be for the HS Spar.

TC

TCHoles are 1/2” either side of Topcenter and 1/2” from the back endof the TC.

1/4”

1/2”

CPS

TC

STEP # 15

1 1/2”

1”

2 1/2”

Take a piece of 1/16” Rod, 5”long, and bend it as shown.

Mount a 1/2” Wheel onto theend as shown.(I used a Sullivan TailwheelNo.350 from Tower Hobbies)

OR...

You can also just use a piece of3/32” Rod, 5” long, and bend aloop in the end as the tail wheel(See Page 36).

STEP # 16

Take the Tail Wheel Rod and insert it into the backend of the Tail Cone. Take a piece of 3/32” Rod,4” long, and insert it through the HS holes you madein Step 14. (The HS Rod should lock in the TailWheel Rod).

STEP # 17

Fill the back end of the Tail Cone with Hot Glue tohold the HS Rod Spar and the Tail Wheel Rod inplace. (Squeeze the Tail Cone closed)

STEP # 18

For the Main Landing Gear (MLG),take a piece of 3/32” Rod, 8 1/4”long, and bend it as shown on Page36. Insert it through the holes youmade in the front of the Cockpit inStep # 13 and glue it in place.

(I used my Hot Glue Gun for this.)

MLG

..

3/4”

Note that the MLG slants Backward3/4” from the front of the Cockpit.

STEP # 19

Now close the front Top end of the Cockpit.

You can, at this time, mount all of the wheels onto your plane but do not secure them permanently just yet.

www.bcair.comYour plane should now look something like this.

For the Main Wheels I used, 1” Sullivan Tailwheels - No. 352, from Tower Hobbies.

You can also make your main wheels from Bottle Caps. Take Two Caps and put a 3/32”hole in the center of each cap. Glue Two Caps together to make one wheel.

Note: Be sure to make the 3/32” WS Holes,in the Can that covers CPS, where indicated.

STEP # 20 - Engine

(I used contact cement for this.)

Take any Eight (8) Bottle Caps and put a 3/32” hole in the centerof each Cap. Slide the Caps onto a piece of 3/32” Rod, 6” long,and glue them together, and TO THE ROD, as shown. This willbe the Engine Crank Case (ECC).The Rod will serve as the Prop Shaft (PS).

(I used 2-Part Epoxy for this.)

Now glue the Two EC to either side of the ECC as shown.EC EC

EC EC

ECC

ECC

PS

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Leave atleast 2” ofRodextendingfrom theFRONTEnd of theECC.

Take Five (5) Pull Tabs andglue them into a stack. Use astrip of tape to hold them inplace until the glue is dry.Make Two (2) stacks.These will be the EngineCylinders (EC).

Glue on the INSIDE

STEP # 22

STEP # 21

STEP # 23

Cut Off the excess PS,from the Back of theEngine and glue theEngine onto Template #6, Page 33, as shown.Note: Be sure Template# 6 matches up with theFront End of theCockpit.

Cut Template # 7, Page35, Engine Cowl (EC),from a Can and shapeinto a cone. Hold it’sshape, on the OUT-SIDE with a piece ofclear tape and glue onthe INSIDE.

Slide the EC over the Engine and Template # 6 and glue in place.

STEP # 24

Glue the EC assembly onto the Front of the Cockpit.

STEP # 25

STEP # 26

Take a small piece of Popsicle Stick, or heavy Card Stock, and glue it to the MLG as shown.(I used 2-Part Epoxy for this). When the glue is dry, wrap the MLG with a piece of Duct Tape.

Cut Two (2) (WP) Template # 8, Page 34, from Cans and fold into shape. Hold their shape with a strip of Clear Tapeon the Outside and glue on the Inside. (I used contact cement for this). Once the glue is dry you can trip off the excesstape. These are the Wheel Pants.

STEP # 29

STEP # 27 - Air ScopeSTEP # 28 - Engine Exhaust Pipes.Cut Template # 9 - AI - (Page 36) from Can and glue in

place under the EC.Glue Two small pieces of tubing into the Bottom of the EC.

Notch the Wheel Pants on the Inside and glue them in place.

(I used 2-Part Epoxy for this).

Remount the MLG Wheels.

Cut Two Template # 10, WCB, and Two Template # 11, WCBAF, (page 33), from corrugatedcardboard. Glue/Stick the WCBAF onto the Top of the WCB, 1/4” back from the leadingedge. (I used double face tape to do this.)

WCBAF

WCBAF

WCBWCB

Top Right Wing

1/4”

<--Corrugation Runs-->

Put a strip of double face tape on the Underside of the WCB and cover the Bottom of thewing with a Can, trim to shape as shown. Leave 1/4” overlap of the WCB in the Bottom Can.

Leave 1/4” overlap of theWCB in the Bottom Can.

Bottom View Right Wing

Top View Right Wing

STEP # 30

Put a strip of double face tape on the Top of the WCBAF and coverthe Top of the wing with a Can. Trim Can for a tight fit and fold overthe edges as shown above. Repeat this Step for the Left Wing.

STEP # 31 Take Two pieces of 3/32” Rod, 10” long, and bend them as shown here.1/4”

5”

5”

Insert the WS Rods through Holes A & B in the Cockpit, (Be sure Wing Spars are parallel with each other). Put someglue/epoxy on the wing spars and on the WCB where the wing will come in contact with the plane’s body and slide thewings into place.

These are the Wing Spar Rods.

Your plane should now look something like this.

(I used 2-Part Epoxy to do this.)

www.bcair.com

Note: Bottom Wing Can overlaps Cockpit Bottom.

Leading Edge of Wings should be 1/4”Back from back end of the MLG.

STEP # 32HS

STEP # 33

VS

Cut Two (2) HS, Template # 12 - Page 34, from corrugatedcardboard and cover with Cans just as you did the Wings.

Cut VS, Template # 13 - Page34, from corrugated cardboardand cover with Cans just as youdid the Wings.

STEP # 34

Put some glue/epoxy on the HS Rod, and on the HS whereit will meet the Tail Cone, and slide the HS into place.

Make a 3/32” Hole in the Top Center ofthe Tail Cone, 1/2” Forward from theback end of the Tail Cone as shown.

STEP # 35

Take a piece of 32” Rod, 1” long, and glue it into theBottom of the VS where it will insert into the Hole you makein the Top of the Tail Cone in Step # 34.

VS

TCPut some glue/epoxy on the VS Rod and on the VSwhere it will contact the TC and secure the VS in placeas shown.

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

STEP # 36

HS

Make a 3/8” long Slit in the Top Center ofthe Cockpit just Forward of the IP asshown. This will be where the Front Tabof the Cockpit Bubble will be inserted.

Take any clear 1liter plastic bottleand remove thelabel (A). Markthe bottle asshown (B). Cutthe bottom of thebottle off (C), thencut up the side ofthe bottle (D) andcut the top off (E).

CPB

A B C

D E

Trace Template # 14, page 36, onto the plasticbottle as shown and cut out the CPB.

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STEP # 37

Cockpit Bubble

STEP # 38

Insert the Front Tab, of the CPB, into the Slityou made in Step # 36 and make Slits for theSide Tabs where needed. Glue the CPB inplace.

STEP # 39

Use Duct Tape and mask offthe CPB as shown.

STEP # 40

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Glue a small Flat Headed Nail into theTop of the VS and into each of theWing Tips as shown. (Push the nail allthe way in.)

Use a magic marker, or paint, theRight Wing Tip Nail GREEN andthe Left Wing Tip Nail and the VSNail RED.

Put a small “bubble” of Hot Glue oneach Nail Head.

(These are the planes navigationlights.)

VS Light

Right WingNav Light

Left WingNav Light

Take a piece of 1/16” Rod 2 1/2” long and bend and glue it into theTop Center of the TC, 1/2” Back from the CPB as shown.

TC

CPB

STEP # 41

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.

You can use a 4”, 5”, 6” or 7” Prop, 2,3, or 4 blade, with whatever pitch youdesire, depending on the plane you’rebuilding.

Install the Prop and cut off theexcess PS. Be sure that theProp spins freely. Glue theProp Spinner to the Prop.

On this plane I used a propfrom Tower Hobbies(www.towerhobbies.com).Prop # LXZ947 and painted itSilver.

Cut the Prop Spinner Tem-plate # 15 (Page 36) from aCan and shape into a cone.Hold it’s shape with a strip oftape on the OUTSIDE. Gluethe Spinner on the INSIDE.Glue Spinner to the Prop.(You can also paint the Spin-ner if you like.)

STEP # 42

STEP # 43

Your B. C. Air Originals Van RV-7 is now complete.

STEP # 44 Show ALL your friends your completed plane !

Flip

to g

et L

eft a

nd R

ight

Win

g.

WC

B

WC

BA

F

CPF

Blue Lines are Score Lines

Template # 1

Templates # 2

33

CPS..Wing Spar Holes

Use the Front part of thisTemplate to getTemplate # 6

Tem

plat

e #

10

Tem

plat

e #

11

8 1/4”

2 1/2”

HS

Leading Edge

34

VS

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Template # 5

Template # 8

WP

Template # 13

Template # 12

35

Engine Cowling

EC

TAB

TC

Blue Lines are Score Lines

TAB

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Template # 4

Template # 7

PropSpinner

Tab

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A

B

Match up A with B

B

A

36

CPB

Tail Wheel

Main Landing Gear

Template # 9

AI

Template # 14

Template # 15

37

Seat Bottoms

Seat Backs

Instrument Panel - IP

<--Corrugation Runs-->

Template # 3You may use the Seat BacksWith or Without the HeadRests.