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B.C. Air PA-28-140 Manual

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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.
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Thank You & Enjoy!
Wayne

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Summary of Contents for B.C. Air PA-28-140

  • Page 1 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.
  • Page 2 36 Pages With Over 125 Full Color Photos showing how to build the Piper Cherokee FROM CANS ! Wingspan: 17” Length: 14” PA-28-140 Height: 4 1/2” Can be made from most 12 or 16 oz Beverage Cans. www.bcair.com Copyright © 2013 B.
  • Page 3 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.
  • Page 4 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..
  • Page 5 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).
  • Page 6 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. ®...
  • Page 7 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.
  • Page 8 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 Pull Tab STEP # 1 Once you’ve selected which Cans you’ll be using to make your plane out of,...
  • Page 9 STEP # 4 Score CPF where indicated. STEP # 5 Cut TWO pieces of corrugated Cardboard 1 1/2” x 3 3/8” 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.

  • Page 10: Table Of Contents

    Template # 2 <--Corrugation Runs--> Template # 3 Cut Templates # 2 & 3 (Page 33) from corrugated cardboard as shown. STEP # 7 Note how WSF fitts onto EM. STEP # 8 Glue EM inside CPF as shown. (I used my Hot Glue Gun for this.) STEP # 9 Glue WSF onto EM as shown.

  • Page 11: Step # 10

    STEP # 10 Cut TWO pieces OF THE FRONT END of Template # 2 (EM) from corrugated cardboard. 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”...

  • Page 12: Template # 4

    STEP # 12 Marry Two Cans, from Step # 2, together as shown here. Glue on INSIDE 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.

  • Page 13: Template # 5

    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.) Template # 5 STEP # 15 Cut out Template # 5 (TCF), page 33, from corrugated cardboard and put a “thin”...
  • Page 14 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.
  • Page 15 STEP # 18 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). STEP # 20 Paint the INSIDE of the WS black.
  • Page 16 Trim EM if necessary. WS SLIT WS SLIT Place WS in position (on the CPF) and mark the STEP # 21 CPF where slits will be needed for the WS Tabs. Glue WS in place on top of EM and CPF as shown. STEP # 22 (I used Hot Glue for this.) www.bcair.com...
  • Page 17 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.
  • Page 18 STEP # 25 Glue CPC in place onto the WS, TC and CPF as shown. (I used Hot Glue and 2- Part Epoxy for this.) www.bcair.com STEP # 26 Cut out Template # 8, EC (page 35), and glue it into it’s shape as you did with the TC.
  • Page 19 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...
  • Page 20 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. (I used 2-Part Epoxy to do this.) www.bcair.com...
  • Page 21 This is how I do it. 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. The trick is not to try and cut the thing out in one...
  • Page 22 1/4” STEP # 30 WCBAF Cut Two Template # 10, WCB, and Two Template Top Left Wing # 11, (page 36), WCBAF, from corrugated card- <--Corrugation Runs--> board. 1/4” Glue/Stick the WCBAF WCBAF onto the Top of the WCB, 1/4” back from the leading edge.
  • Page 23 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...
  • Page 24 Make Wing Spar Holes in CPC as shown (BOTH SIDES). STEP # 33 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”...
  • Page 25 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...
  • Page 26 STEP # 36 Cut Template # 12, VS, (page 34), and Template # 13, HS, (page 35), from corru- gated cardboard and cover with Cans as you did the wings. <--Corrugation Runs--> STEP # 37 Take Two pieces of 3/32” Rod, 1” long and glue them into the Base of VS as shown.
  • Page 27 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...
  • Page 28 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 shown. Rod will go through the HS Holes (I used 2-Part Epoxy for this.) that you made in the Tail Cone.
  • Page 29 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 secure.
  • Page 30 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 and the VS...
  • Page 31 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”...
  • Page 32 Wheels Here are Two options for your Wheels. STEP # 44 (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.
  • Page 33 STEP # 46 Insert MWLG into the holes in the bottom of the wings and work them “through” the WCB into place. Glue in place. 1 2 3 Wheel 1 2 3 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 MWLG 1 2 3 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0...
  • Page 34 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.
  • Page 35 Templates # 3 1 7/8” Blue Lines are Score Lines Template # 1 Template # 5 3 1/2” 1 3/4” www.bcair.com Templates # 2...
  • Page 36 Template # 9 www.bcair.com Template # 4 7 3/8” Blue Lines are Score Lines OVER TAB Template # 12...
  • Page 37 Leading Edge Template # 13 www.bcair.com Blue Lines are Score Lines Top Center Template # 8 Engine Cowling 8 1/4” Template # 7 OVER TAB OVER TAB...
  • Page 38 Match up A with B Template # 6 Windshield www.bcair.com 3”...