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.30 Pages With Over 120 Full Color Photos showing how to build the

Can be made from most12 or 16 oz Beverage Cans.

Wingspan:13 1/2”Length: 14 1/4”Height: 4 1/2”

Jedi X-Wing Starfighter

TOP SECRET

Welcome to the B. C. Air Originals Squadron.

This booklet contains complete step by step instructions for building the B. C.Air Originals Jedi X-Wing Starfighter. Before you start building your firstplane it is suggested that you review the entire set of plan directions. Once youhave previewed the construction steps you should start collecting the cans thatyou want to use to make your first plane. These plans are designed to be usedwith any 12 or 16 oz. Beverage can. Always use clean, un-scratched and un-dented cans for the best looking planes.

Since the building of these planes requires the cutting of cans and the use ofsharp tools, CHILDREN SHOULD NEVER ATTEMPT THE CONSTRUC-TION OF THESE PLANES WITHOUT ADULT SUPERVISION ANDGUIDANCE. CONSUMER ACCEPTS ALL RESPONSIBILITY FOR ANYINJURY INCURRED IN THE BUILDING OF THESE PLANES.

It is not necessary to follow all the building steps in the order presented. Suchas, if you want to make the Engines or the Lasers first, you can do that and thenset them aside until you need them. However, until you understand the construc-tion of these planes, it may be easier to follow the steps in the order listed. Yourvery 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 youcan 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 freeto 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 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 this plane.

TOOLS:

Pliers.Push Pins.Hot glue gun.Wire cutter.X-acto knife (hobby knife).ScissorsRuler (straight edge).Felt tip pen (any color).Needle nose pliers.

Paper Cutter. Ball Point Pen.

Materials :21 Aluminum Cans (beer, pop, soda, juice, etc.) any 12 or 16 oz. size will

work.9 Bottle caps (any kind).1 Piece of Corrugated Cardboard 7” x 12”. (Grain running the 12” way.)Tape (any kind)

Glue or 2-Part Epoxy.3/32” Copper Coated Welding Rod, Music Wire or any other straight wire.4 Hazel Nuts (Acorn Nuts, Cap Nuts).12 - 10/24 Nuts and 4 8/24 Nuts

(or whatever you happen to have access to). 28 - #4-#6 Stud Ring Electrical Terminals.

www.bcair.com

Cutting CansThe building of these planes requires that the Tops and/or Bottoms of beverage cansbe cut off. While you can decide for yourself which method you use to accomplishthis, 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 boardwood (aprox 12” x 15” x 3/4”) and to it I’veattached (screw or glue) Two Blocks of wood(2” x 2” x 5”) and Two Rails of wood (1” x1” 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, then cutthe Top off. Get asmuch of the Can aspossible.

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 isthe way Icut theCans tomake thisplane.

STEP # 1

STEP # 3

STEP # 2

You will need 21 Cans to make this plane.Once you’ve selected which Cans you’ll beusing to make your plane out of, take oneCan and designate it as Can B-1.

B-1Take Can B-1 anddecide where youwould like the Bottomof the plane to be.Draw a like down theBelly of the plane. B-1

Cut out Template # 1(Next Page) and tapeit around Can B-1.

Line up the BottomCenter of Plane Linewith the line you drewon the Can.

Push Template #1 allthe way down to thebottom of the Can.

B-1

B-1

.

A

G

.

.

To th

e FR

ON

T of

the

Plan

e

TEM

PLAT

E #

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.

. .

. .

.

B

C

E

D

F H

TOP CENTER OF PLANE

BOTTOM CENTER OF PLANE

. .I J

Slit R-1

Slit R-2

Slit L-1

Slit L-2

www.bcair.com

STEP # 4

STEP # 5

STEP # 6

Use your Push Pins and makeHoles “A” through “J”.

Use yourX-Actoknife andmake SlitsL-1, L-2,R-1 & R-2.

Remove all of your Push Pins and removeTemplate # 1 from the Can. Enlarge Holes“A” through “J” to 3/32”. Take Four (4)pieces of 3/32” Rod, each 8” long, and insertthem into B-1 as shown. (A through B - C through D - E through F - G through H) (This is just to check to make sure that the Wing Spars will line up with each other.) If you’resatisfied with the way the Rods line up then remove the Rods and set B-1 aside for now.

B-1

B-1

(Remove Pull Tab)

STEP # 7

CanCellophane TapeDouble-Sided Tape

Take the remaining 20 Cans and removetheir Tops and Bottoms. Open the Cansup and trim them to 3 5/8” x 8 1/4”.

Now take Three (3) of those Cans andmarry them together as shown here.

STEP # 8

Cut Template # 2 (B-2), Page 29, from the three Cans you married together in Step # 7

STEP # 9

B-2

B-2

Use your Ball Point Pen, and your ruler, and Score the INSIDEof B-2, on the lines where indicated on Template # 2.

Score

STEP # 10 Form B-2 into a cone, overlapping the Tab, and tape together to hold it’s shape.

Cellophane Tape

www.bcair.com

B-1

B-2

STEP # 11

Glue B-2 in the INSIDEwhere it overlaps the Tab..Use any good householdcontact cement, like QuickGrip or Welder.

Use your magic marker to help shape the nose end of B-2.

B-2

B-2

B-1

B-2

STEP # 12Put Glue in the INSIDE of B-2 and secure to theFRONT of B-1. Be sure to line up the Bottom ofB-2 with the line you drew on the Belly of B-1.

STEP # 13

Once B-2 is secure to B-1, use yourX-Acto knife and cut open the Pilot’sseat from B-2 (where indicated onTemplate # 2)

Bend “Half” of the Pilot’s seatstraight up as shown.B-2

B-2

STEP # 14

Bend the “Back Side” of the Pilot’sseat straight down as shown.

STEP # 15

Use your small scissors andenlarge the cockpit accessby 1/4” on all Three (3)sides as shown.

www.bcair.com

STEP # 16Print out thecockpit interior(page 28) ontowhite card stock(heavy paper).

Fold the cockpitinterior andmanipulate itinto positioninside B-2.

When you haveit where youwant it, securewith glue.

STEP # 17

Tape the edges of thecockpit to soften them.

S-foil Servo Actuator

STEP # 18

Take Two (2) Cans and marry them together asyou did in Step # 7. Cut Template # 3 (BB),page 30, out of these Cans.

Use your ball point pen and score BB on theINSIDE where indicated.

Enlarge Holes “I” & “J” (in B-1) to 1/4”.

Take Two (2) pieces of cardboard 1” x 3 1/2”and glue them together, then put glue on theINSIDE TOP of BB and stick the cardboard toit. Now put some glue around Holes “I” &“J” (on B-1). Put some glue on the INSIDE ofBB’s Tabs and insert them into Slits L-1, L-2,R-1 & R-2. Hold BB in place with tape untilglue has dried.

BB

12345678901231234567890123

12345678901231234567890123

B-1

BBBB

STEP # 19

B-1

Fill in the back end ofB-1 & BB with HotGlue. Using your HotGlue Gun, make what-ever kind of a designyou like on the back ofB-1. Then paint (or useyour Black MagicMarker) the back endof B-1 Black.

STEP # 20

Take a 1 Liter PlasticBottle and cut it asshown.

Take Template # 4, the TransparisteelCanopy, ( Page 30), and tape it to theBottom of one of the plastic pieces youcut from the bottle. Mark the plasticpiece and cut out the Canopy. Use yourball point pen and score the Canopy, onthe INSIDE, where indicated

1 2

3

4

5

6

7

8

www.bcair.com

STEP # 21

STEP # 22 Glue a Pull Tab onto the back of the seat as a head rest.Glue a Joy Stick into the floor of the cockpit interior.

STEP # 23

Glue the Transparisteel Canopy inplace and outline with tape asshown.

STEP # 24 Cut Template # 5, Nose Cone, page 28, from a piece of Can and form it into shape.Glue the Nose Cone to the Front of B-2.

STEP # 25 S-foil Wing Assembly

Cut Four (4) Template # 6, (page 30) Wings,from your 7 x 12 piece of corrugated card-board and cover them with Cans as shown.

<-- Corrugation Runs -->

Put a spot of glue in several places on theWing cardboard to help hold Cans inplace.

This is the UNDERSIDE of the Wing.

S-foil Wing Assembly. STEP # 26

Insert Two Wing Spars, from Step # 6, into Holes “A” & “B” and“C” & “D” in B-1. Put some glue on the end of the wing and on theWing Spar Rods. Slide Wing onto Wing Spar.

Push Winginto place andhold with tapeuntil glue hasdried.G

LUE

Secure all Four Wings into place.

Note the way the Wings areattached. The Wing Bottomsface each other.

Bottom of WingTop of Wing

Top of Wing

Bottom of Wing

www.bcair.com

Incom 4L4 Fusial Thrust Engine.STEP # 27

Take 8 Bottle Caps and put a 3/32” hole through the center ofeach cap. (Optional: Then spray paint them Black.)

STEP # 28Take Four (4) pieces of Can, 2 1/4” x 3 5/8”and roll it into a cylinder as shown above.Wrap Can around a couple of Bottle Capsand tape the ends together. These will be the REB’s.

2 1/4”

STEP # 29Take One of theBottle Caps andinsert it into oneend of REB to adepth of 3/4”.

Glue the BottleCap to the insideof REB.

Insert a SecondBottle Cap intothe other end ofthe REB, flush tothe end.

REBREBREB

REB

REB

2 1/4”

3/4”

12341234123412341234123412341234123412341234

12341234123412341234123412341234123412341234

STEP # 30Take Three pieces of Can (for each engine), 3/4”x 1 1/4” and shape each piece as shown. Thesewill be the Air Fins for the Front of the engines.

Bend Air Fins around a piece of 3/32” Rod 2 1/2” long (AFR).

Put a spot of Hot Glue on the end of theAFR Rod/Fins and Trim Fins to fit insidethe Front of REB. Glue the AFR Rod tothe Back Bottle Cap.

Incom 4L4 Fusial Thrust Engine.

REB

REB

STEP # 31

Incom 4L4 Fusial Thrust Engine.

REE

REE

REE

1 3/4”

REETake Four (4) pieces of Can, 2 1/4” x 1 3/4” and roll it into a cylinder as shown above.Tape the ends together. (Ends do NOT overlap) These will be the REE’s.

Take 7 electrical wire terminals (for eachengine) and remove the plastic insulator, (TI)Stack the plastic insulators together as shown.

STEP # 32

Slide REE over the plasticinsulators and push theinsulators all the way intoREE until they are flushwith the end as shown.

TI

TITI

www.bcair.com

123456781234567812345678123456781234567812345678

12121212121212121212

12121212121212121212

AF

Bottle Caps

Tape

AFRTI

REB REEREAB

STEP # 33

Incom 4L4 Fusial Thrust Engine.

Take a piece of Can3/4” x (slightly over)2 1/4” and score linesapprox. 1/8” apart asshown.

Roll around end ofREE and glue inplace.

123456789012345678901234567123456789012345678901234567123456789012345678901234567123456789012345678901234567123456789012345678901234567123456789012345678901234567

REE

Accent engines with tape as shown.

Glue REE into the Back of REB.(Note Position) When the engine ismounted, all slits in the Cans shouldface the planes body. The Air Finsshould line up with the Wing.

TI

Use your X-Acto knife and make ThreeGlue Holes in the Bottom of REB.

TI

12345678123456781234567812345678123456781234567812345678

Top of Engine

Glue holes in Bottom of REB

. . .STEP # 34Place engine in position on wing and mark wingwhere engine comes in contact with it. The correctposition for the engine is the thickness of a piece ofcorrugated cardboard away from the BB. Make glueholes in the wing where the engine will mount.

Note how the engineextends forward ofthe wing.

GLUE HOLES

Put glue on the holesin the bottom of REBand on the glue holeson the wing. Mountengine to the wing andhold in place with tapeuntil glue is dry.

REB

REB

www.bcair.com

Deflector Shield Generator and Power Generator

STEP # 35

After attaching allfour engines, yourplane should nowlook similar to this.

Cut out and glue on, theDeflector Shield Generatorand Power Generator decalfrom page 28.

Deflector Screen Projector.

STEP # 36

Cut Four Template # 7 (DSP), page 30, outof Cans and secure in place as shown.Scratch the Inside of DSP to give the gluesomething to hold on to. Glue on the Insideof DSP.

DSP

DSP

DSP

DSP

DSP

WING

WING

WING

REB

REB

www.bcair.com

KX9 Laser Cannon.3/32” Rod 7 1/2” long.

2” wide x 2” long piece of Duck Tape wrapped around 3/32” Rod.

2” wide x 6” long piece of DuckTape wrapped around 3/32” Rod.

8/24 Nut

Can piece3/8” x 3/4”

10/24 Nuts

Washer

1/4” x 2”Black Tapewrappedaround 3/32” Rod

2” wide x 15” long piece of Duck Tape wrapped around 3/32” Rod.

Drop ofHot Glue.

STEP # 37 Make Four (4) Lasers asshown here.

Take Two of the ElectricalTerminals, from Step 31,flatten them, and tape and gluethem to the Bottom of the

STEP # 38

Laser as shown.

Make slits in the Wing Tips where you want yourLasers to go. Put glue on the ends of the TerminalConnectors and in the Wing Slits and attach theLasers to the Wings.

www.bcair.com

The Astromech Droid.STEP # 39

Take a BottleCap and put a 3/32” hole in thecenter. Hold theCap with yourneedle nosepliers and dropsome Hot Glueon the Top of it.

When the Hot Glue is the shape that youwant it, dip the Cap into ice cold waterto set the Hot Glue in place.

Spray paint the Glue andCap silver.

Make a glue hole in thetop of BB, near theCanopy, and glue theBottle Cap in place asshown.

STEP # 40

Your B. C. Air Originals Jedi X-Wing Starfighter is now complete !

, ,,,

*^^

^ ^

Page 28

3” x 3 3/4”

Template # 5Nose Cone

Cockpit Interior

Deflector ShieldGenerator andPower Generatordecal

Blue Lines areSCORE LINES

www.bcair.com

TAB

Top

Cen

ter o

f Pla

nePi

lot’s

S

eat

Blue lines are SCORE LINES, DO NOT CUT.

TEMPLATE # 2B-2

Page 29

www.bcair.com

Top

Cen

ter o

f Pla

ne

Blue Lines are SCORE LINES.

Template # 3 BB Template # 4

Transparisteel Canopy

Template # 7 DSP

Page 30

Tem

plat

e #

6 W

ings

3 3/4” x 4 1/2”

2 3/8” x 2 5/8”

2 7/

8” x

5 1

/2”

www.bcair.com