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B.C. Air Republic P-47D Thunderbolt Step By Step Construction Manual

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Summary of Contents for B.C. Air Republic P-47D Thunderbolt

  • 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 Step By Step Construction Plans. 37 Pages With Over 170 Full Color Photos showing how to build the Republic P-47D Thunderbolt Wingspan: 16” Length: 14” Height: 5” Can be made from most 12 or 16 oz Beverage Cans. www.bcair.com Copyright © 2013 B.
  • Page 3 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.
  • 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 13 Cans to make. STEP # 1 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”...
  • Page 9 STEP # 3 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. Pilot’s Seat STEP # 5 Using your fingers, Two inside at the Top and One inside at the Bottom, PULL the Can Rim into the shape shown.
  • Page 10 STEP # 6 Print out the Instrument Panel (page 35) onto Card Stock, cut it out and glue it in place inside the Cockpit. Glue the IP to the INSIDE of B-1 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.
  • Page 11 STEP # 8 Cut the Tops and Bottoms off 10 Cans and open them up as shown here. (See Page 6) GET AS MUCH OF THE CAN AS POSSIBLE Marry Two Cans, from Step # 8, together as shown here. STEP # 9 Glue on INSIDE Cellophane Tape...
  • Page 12 STEP # 11 Put some glue around the INSIDE rim of B-2. The Overlap of the Cans, on B-2, should be on the BOTTOM of the Plane. 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.
  • Page 13 STEP # 12 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 # 13 Use your X-Acto knife and rough cut the Bottom of the Can off.
  • Page 14 STEP # 15 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 &...
  • Page 15 STEP # 17 WCBAF Cut TWO WCB & TWO WCBAF (Templates # 3 & 4 - page 37) and glue the WCBAF (1/4” back from the leading edge) <--Corrugation Runs--> on Top of the WCB as shown. STEP # 18 Cover the Top of the Wing with a Can.
  • Page 16 STEP # 19 Cover the Underside of the wing by gluing a Can to it cut to the same shape. Note that the Bottom Can extends 1/4” beyond the WCB where the wing will meet B-1. www.bcair.com Glue Glue STEP # 20 Take a piece of Can 1”...
  • Page 17 7/8” STEP # 21 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.
  • Page 18 STEP # 22 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”...
  • Page 19 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 1/4” 1/4” from end of Tail Cone and 1/4”...
  • Page 20 STEP # 26 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.
  • Page 21 STEP # 29 Cover the VS with Cans as you did the HS. www.bcair.com STEP # 30 Take a piece of 3/32” Rod, 17” long, and put a 1 1/2” right angle bend in it at one end. This will be the Prop Shaft (PS).
  • Page 22 STEP # 32 Take the PS (from Step # 30) and insert it through the Back End of the Tail Cone, through the 1/4” hole in the Back of B-1 and out through the Front of B-3. Put some Epoxy/Glue on the Rod end.
  • Page 23 STEP # 34 (Making the Joy Stick) Take One #4-#6 Stud, 16-14 AWG, Ring electrical terminal (ET) and remove the plastic insulator (A). Take a piece of 3/32” Rod, 1” long, and glue the ET onto one end of it (B). Take a piece of rubber insulation and tip the other end of the Rod as shown (C).
  • Page 24 STEP # 37 The cockpit canopy (CPC) and forward windshield (FWS) are made from a clear plastic bottle. The one shown here has the right curvature to it (I got it at Wal-Mart). Trace Templates # 7 & 8 - Pages 36 & 37 (CPC & FWS) onto it.
  • Page 25 STEP # 38 Place the CPC in position and make slits in B-1 where needed. The Front of the CPC should be even with the Front of the Instrument Panel. Glue the CPC in place. STEP # 39 Place the FWS in position and make slits in B-1 where needed.
  • Page 26 STEP # 41 - Engine Stack 6 or 7 Pull Tabs, hold in place with a strip of tape, and glue/epoxy them Take 4 bottle caps and put together. Make 7 stacks of Tabs. a 3/32” hole in the center of These will become the Engine Cylinders (ECS).
  • Page 27 3/32” or 1/16” Rod - 1 1/4” long * OPTIONAL METHOD FOR ADDING VALVE PUSH RODS * Glue bottle cap, with 3/32” Hole in the center, over face of engine www.bcair.com to finish off push rods.
  • Page 28 STEP # 42 (Engine Cowling) Take another Can and wrap Template # 9 -Page 35 around it as shown. Mark the Can all the way around. Use your X-Acto Knife and rough cut the Bottom off. Move the Template slightly up and then use your scissors to clean trim the Cowling.
  • Page 29 STEP # 43 Take the Engine (Step # 41) and slide it onto the PS. Glue it all the way up against B-3. STEP # 44 Put some Glue/Epoxy INSIDE of the Engine Cowling and slide the Cowling over the engine and up onto B-3. Hold in place until Glue/Epoxy is dry.
  • Page 30 STEP # 46 Canopy (Radio Antenna) Glue 1/16” Rod, 3” 1” long, (1” back from the Back of the Canopy) into B-2. Glue a piece of Can over the Rod. Glue a Straight Pin into the VS as Shown. Tie a piece of String between the Pin and the Rod. 1”...
  • Page 31 STEP # 48 (Bombs) The Bombs are made from your old Sharpie Marking Pens. Remove the clip, cut the barrel end to whatever length you like and glue it into the Cap. Glue Template # 11 (BTF - page 35) around the back end and glue a 1”, 3/32”...

  • Page 32: Step # 50 - Optional Landing Gear

    STEP # 50 - OPTIONAL LANDING GEAR Take Four (4) Bottle Caps and put a 3/32” Hole in the center of each Cap. Paint them black and glue Two Caps together to make one wheel. Add Wheel Hubs (page 35). 3/4”...
  • Page 33 2 1/2” STEP # 52 Glue Main Landing gear into wing as shown (just to the inside of the first gun). Glue Tail Wheel & Tail Wheel gear door (Tem- plate # 12 - page 35) into Tail Cone as shown. 1 1/2”...
  • Page 34 Acorn Nut or Toothpaste Cap. On this plane I used Two props (to make One 4-blade prop) from Tower Hobbies (www.towerhobbies.com). Prop # LXZ944 OPTIONAL Add Victory Markings and Nose Art as you like. Your B. C. Originals Republic P-47D Thunderbolt is now complete.
  • Page 35 When printing out this template. X to X MUST be 8 1/4” X to Y should be 5” TEMPLATE # 1 Center Bottom of Plane www.bcair.com...

  • Page 36: Instrument Panel

    Instrument Panel (Print out on Card Stock) Template # 12 Tail Wheel Door TEMPLATE # 9 Bottom Center Of Cowl Trim Fins to desired shape. Wheel Hubs...
  • Page 37 * WHEN CUTTING OUT THESE TEMPLATES, CUT IN THE INSIDE OF THE LINES * TEMPLATE # 7 (Match up A with B) Template # 2 Top Center of B-2 TEMPLATE # 6 <--Corrugation Runs--> www.bcair.com...
  • Page 38 * WHEN CUTTING OUT THESE TEMPLATES, CUT IN THE INSIDE OF THE LINES * www.bcair.com BTTC Template # 8 Template # 13 Main Landing Gear Door...