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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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This booklet contains complete step by step instructions for building the B. C. Air Originals - Pilatus PC-12 NG. Before you start building your first aircraft it is suggested that you review the entire set of plan directions. Once you have pre- viewed the construction steps you should start collecting the cans that you want to use to make your first plane.
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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..
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The following is a list of tools and materials I use to build these models. 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).
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Cutting Cans The building of these models 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. ®...
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Another Way Of Cutting Cans (This is the method I used to make this Model.) Once you’ve selected which Cans your model 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.
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STEP # 1 <--Corrugation Runs--> Cut ONE (1) Template # 1 (F-1), Page 52, from corru- gated cardboard. Be sure that the “center” corrugation is in the Center of the F-1 as shown. Template # 1 Template # 3 Template # 2 Cut TWO (2) Templates # 2 (F-2), TWO (2) Templates # 3...
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This Airplane takes a total of 20 Cans Cardboard Formers for the Front of the Plane. to make. It is designed to be made from most 12 oz. beverage Cans Template # 1 can easily be made from the larger 16 oz.
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Center Corrugation STEP # 3 Take a piece of 3/32” Rod, 10” long, and insert it through the Bottom center hole and the hole in the center of the lettle button in the Top of the Can as shown above. Now slide F-1 onto the Rod as shown.
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Center Corrugation STEP # 4 Use your Hot Glue Gun and glue BOTH F-2’s onto F-1 as shown. DO NOT GLUE F-2’s ONTO THE CAN. STEP # 5 REMOVE F-1 and F-2’s from the Can and glue BOTH F-3’s in place where indicated, as shown.
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STEP # 6 Glue BOTH F-4’s in place where indicated, as shown.
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Center Corrugation STEP # 7 Take the Rod, from Step # 3, and insert it through the Center of F-5 as shown above. Then insert the Rod into the Center Corrugation of F-1 and glue the Rod and F-5 in place as shown.
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STEP # 8 Glue Fourteen (14) Pennies, Seven (7) on each side of F-1, just in Front of F-4 as shown. (Also glue Ten (10) additional Pennies, Five (5) on each side of F-1, just Back of F-4. See Step # 28) You will need these as Nose weight to keep the plane from falling on it’s tail.
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STEP # 9 3/32” Holes Take another Can and designate it as B-2. Make Five (5) 3/32” Holes, as shown, in the bottom of Cans B-2 as shown STEP # 10 Take a piece of paper 8 1/4” long and 2 1/4” high and wrap it around the Bottom of B-2 as shown.
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STEP # 11 First, rough cut the Top off B-2. Then cut the Bottom off B-2 on the line that you drew around it in Step # Be careful to get a nice clean, smooth cut all the way around the Can. Put a beed of glue around the INSIDE of B-2 STEP # 12 and glue it to the Bottom of B-1 as shown.
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STEP # 14 STEP # 13 Cut out Template # 6, Page 53, and wrap it around Decide where the BOTTOM of your plane will be B-1 & B-2 as shown. and draw a line down the Center of B-1 & B-2 as shown.
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STEP # 15 Use a Push Pin, and make Holes A, B, where indicated. Use Template # 6 and mark the Cans where the TOP CENTER of the plane will be.
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TOP CENTER of the plane TOP CENTER of the plane STEP # 16 Now Glue the Front Plane Assembly (From Step # 8) onto the Front of B-1 as shown. Front of Plane Assembly FLUSH with Top and Botton of B-1. www.bcair.com...
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STEP # 17 Remove the Pull Tabs from Eighteen (18) Cans and cut the Tops and Bottoms off. Then cut them open as shown above. (See Page 6 on “How-To”.) STEP # 18 Take Two (2) Cans, from Step #17, and Marry them together as shown here.
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STEP # 19 Trace Template #7, (TC), Page 52, onto the Two Cans, from Step # 18, and cut it out.
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STEP # 20 Take the TC and shape it into a Cone. Hold it’s shape on the OUTSIDE with clear tape and Glue it’s TAB on the INSIDE as shown. STEP # 21 Put a beed of glue around the INDISE of the TC as shown.
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1 3/8” Top Center of the Plane STEP # 22 Glue the TC onto the Back End of B-2 as shown. Make sure to line up the Top Center of the TC with the Top Center of the Plane. Top View...
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STEP # 23 Cut Template # 8 (LCP), Page 54, from a Can and glue it in place to the Bottom and sides of B-1, F-1, F-2 & F-3 as shown.
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STEP # 24 Cut Template # 9 (TCP), Page 54, from a Can and glue it in place to the Top and sides of B-1, F-1, F-2 & F-3 as shown. Glue Flat against F-1, F-2 and F-3 Top Center of Plane Glue Flat against F-2 and the Sides.
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Top Center of Plane STEP # 25 Make Six (6) slits inthe Back of TCP, to F-2, as shown STEP # 26 Glue the Back end of TCP DOWN onto the Top of B-1 as shown...
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STEP # 27 Cut Template # 10, (EC) Page 55, from Can and shape into a cone. Hold it’s shape on the Outside with clear tape and glue on the Inside. Glue STEP # 28 If you have not already done it, in Step # 8, Glue Ten (10) additional Pennies, Five (5) on each side of F-1, just Back of F-4.
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STEP # 30 Cut Template # 11, (NC) Page 55, from Can and shape it into a Cone. Hold it’s shape on the Outside with clear tape and glue on the Inside. Glue STEP # 31 Glue the NC in place over F-1, EC, and F-5 as shown.
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You should have a total of 24 Pennies worth of weight in the Nose section of your plane. You will need these as Nose weight to keep the plane from falling on it’s tail. Score 1/4” down on the Inside Cut Template # 12, (AS) Page 53, from Can and score as STEP # 32 shown.
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5/8” STEP # 33 Cut out Cockpit Windows, Page 55, and glue in place as shown. 5/8” 1/8”...
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Top Center of the Plane 1 1/4” 1” 1/2” 7/16” 3/4” Cut out Side Windows, Page 55, and glue in place as shown. STEP # 34 1 1/4” 1 1/4” 3/4” 3/4” 1/2” 1/2” 7/16” 7/16” 1” 1” FRONT OF PLANE...
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IF YOUR PLANE WILL BE DISPLAYED WITHOUT LANDING GEAR, SKIP THIS STEP. STEP # 35 Main Wheel LG is swept Back slightly Take TWO (2) pieces of 3/32” Rod 5” Long and bend them as shown for the Main Wheel Landing Gear (MWLG).
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WCBAF WCB - (Left Side) <-----Corrugation Runs-----> <-----Corrugation Runs-----> WCB - (Right Side) These lines on the WCBAF don’t mean anything, they are there just to show the difference between the WCB and the <-----Corrugation Runs-----> WCBAF. STEP # 39 Cut TWO (2) EACH of, Template # 13, WCB &...
IF YOUR PLANE WILL BE DISPLAYED WITHOUT LANDING GEAR< SKIP STEP 40. STEP # 40 Make a 3/32” Hole through the WCB’s, 1 1/4” Back from the Leading Edge of the Wing and 2 1/8” In from where the Wing will meet the Plane’s body, as shown. Leading Edge of Wing Leading Edge of Wing Right Wing...
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STEP # 42 Stick a Can to the Bottom of the WCB and trim off excess. Landing Gear Hole Top View Note that the Can over hangs WCB here. IF YOUR PLANE WILL BE DISPLAYED WITHOUT LANDING GEAR, SKIP STEP 43. STEP # 43 Make the Landing Gear Hole through the Bottom Can.
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Be sure the MLG is positioned straight. Bottom View WCBAF Lay the Wing flat on the table and position the MLG straight and at a 90 degree angle to the (Left Side) wing. Left Wing STEP # 44 Put a strip of double sided tape on the Top of the WCBAF and cover the Top of the wing with a Can, folding the Leading Edge and Trailing Edge of the Top Can over the...
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STEP # 45 Take TWO SETS (3 to a set) of Wire Connectors and sand 1/3 of the connectors off each connector as shown. This is so that the connectors will have a flat side to glue against the wing. Twist-On Wire Connectors.
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Left Side Right Side STEP # 47 Cut TWO (2) Template # 15 (WT) Page 52 from “Chipboard” (like a Cereal Box) and cover them with pieces of Can as shown. Outside Left Side Inside Left Side Be sure to make a TAB on the Outside Can as shown.
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Wing Tip Left Side Wing Tip Left Side STEP # 49 Fill in the gap on the upper part of the wing tip with glue. STEP # 50 Cut a notch 3/4” long into the OWRP as shown. Take an expended Marking Pen and cut 1 5/8” of barrel off the Front end. This will be the Onboard Weather Radar Pod (OWRP).
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STEP # 51 Right Wing Tip Left Wing Tip Glue a small Nail Head into the OWRP and into the Left Wing Tip. Paint Green & Red and put a small bubble of hot glue over the heads. These are the Navigation Lights. STEP # 52 Cut Two (2) Template # 16 MLGD Page 52 from pieces...
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STEP # 54 Enlarge Holes in B-1to 3/32”. STEP # 55 Take Two (2) pieces of 3/32” Rod. One 16” long and the other 10” long and bend them as shown here. 7” 7” 2” 1” 1” 4” 4” 2” 3/4”...
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STEP # 57 Put some glue on the wing spars and insert the completed wings onto the wing spars and glue in place. The Leading Edge of the wings should be 1” from the Back of the LCP. 1” www.bcair.com...
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NWLGD STEP # 58 Cut Template # 17, NWLGD page 55, from a piece of Can. Score on the Inside, where indicated and put a 3/32” hole where indicated. STEP # 59 Take the NWLG and glue a “shock absorber” onto the Front.
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STEP # 60 3/8” Put a 3/32” Hole in the Bottom Center of the EC as shown. Insert the NWLG through the LWLGD and glue the assembly in place as shown. NWLG LWLGD LWLGD LWLG STEP # 61 Cut Two (2) Template # 18, TF page 52, from Chip Board (Cereal Box) and cover with pieces of Can as shown.
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1” STEP # 62 1” Draw Two TF Lines on the Bottom of the TC as shown. TF Line TF Line 3 1/2” 3 1/2” 2” 1/4” 1/4” STEP # 63 Glue the Two TF’s in place on the TF Lines as shown. 1/2”...
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STEP # 64 VS Fin Hole Cut Template # 19, VS page 55, from corrugated cardboard and cover it with Cans. (Don’t forget to mark the Hole for the VS Fins.) VS Fin Hole VS Fin Hole HSMP HSMP HSMP HSMP HS holes STEP # 65...
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STEP # 66 Glue Two small pieces of 3/32” Rod into the Bottom of the VS as shown. Draw a line down the Top Center of the TC and make two corresponding holes for the Rods in the VS. STEP # 67 Cut Two (2) Template # 21, HS page 54, from corrugated cardboard and cover with Cans.
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STEP # 68 Insert Two pieces of 3/32” Rod, 5” long, HSMP through the HS Holes in the HSMP. Put some glue on the Rods and slide the HS onto them. Glue the HS in place as shown.
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STEP # 69 Put a small drop of Clear Hot Glue on the Back End of the HSMP as shown. HSMP This is a Navigation Light. HSMP VS Rods STEP # 70 Insert the VS Rods into the corresponding holes in the TC and glue the VS and HS assembly in place as shown.
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STEP # 71 Insert a small piece of 1/16” Rod through the VS Fin Hole and glue on the Two VS Fins. VS Fin Template # 22, Page 53 VS Fin STEP # 72 Glue the Two RF’s onto a small piece of 1/16”...
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STEP # 74 If you can find a Four Blade Prop you can skip this step. You can make a Four Blade Prop by notching a Two Blade Prop on the Bottom Side of Center and notching another Two Blade Prop on the Top Side of Center as shown.
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STEP # 77 - MANDATORY Your B. C. Originals Pilatus PC-12 NC is now complete. Show it to ALL your friends ! E-mail me a photo of your completed planes and I’ll put them in the Builders Gallery.
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