B.C. Air Republic P-47D Thunderbolt Step By Step Construction Manual Download Page 1

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Summary of Contents for Republic P-47D Thunderbolt

Page 1: ...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 as many of the manuals as they like If you enjoy these planes please help to ensure this site stays on line and these airplane manuals remain available for all to enjoy Any amount ...

Page 2: ... C Air Originals Step By Step Construction Plans 37 Pages With Over 170 Full Color Photos showing how to build the Can be made from most 12 or 16 oz Beverage Cans Wingspan 16 Length 14 Height 5 TOP SECRET Republic P 47D Thunderbolt ...

Page 3: ...PTSALLRESPONSIBILITYFORANYINJURYIN CURRED IN THE BUILDING OF THESE PLANES It is not necessary to follow all the building steps in the order presented Such as if you want to make the Wings or the Tail Section first you can do that and then set them aside until you need them However until you understand the construction of these planes it may be easier to follow the steps in the order listed Your ve...

Page 4: ...nto the BACK BOTTOM of the Can B 1 or use 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 first plane go here http www bcair com BT and look over the Builder s Tips These are building tips sent in from builders all over the world They will help you to make these planes eas...

Page 5: ...rpened to a point Wire cutter X acto knife hobby knife box opener Scissors Can Opener Small 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 ...

Page 6: ...3 4 and to it I ve attached screw or glue Two Blocks of wood 2 x 2 x 5 and Two Rails of wood 1 x 1 x 10 Using a Hose Clamp I ve secured my Dremal Tool to the board The two guide rails are used to cradle the can A cutting wheel is used to cut the Bottom and the Top off the Cans Again you can use any other method at your disposal to remove the Tops and Bottoms of the cans Use whatever means you feel...

Page 7: ...e top off the Can The top will normally tare off right 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 your scissors Next use a smaller scissor to cut the bottom off the Can Use a straight edge or a paper cutter to trim the edges smooth Trim Can to 3 5 8 x 8 1 4 SEE ALL THE BUILDERS TIPS ON LINE AT www bcai...

Page 8: ...ttom of the Can STEP 1 This Plane takes a total of 13 Cans to make B 1 Pull Tab Next make 6 3 32 holes along the bottom rim of the Can as shown STEP 2 Wrap Template 1 page 34 around B 1 and make Holes A B OPTIONAL Make Holes C D ONLY if your plane will have the Belly Fuel Tank Step 47 Make the slits for the Cockpit opening Template MUST be flush withFrontofCan www bcair com ...

Page 9: ...n Bend Half of the Seat straight Up and then bend the other Half of the Seat Down Into the Can Use your Can Opener and cut out the FRONT of B 1 STEP 5 Using your fingers Two inside at the Top and One inside at the Bottom PULL the Can Rim into the shape shown B 1 B 1 Pilot s Seat ...

Page 10: ... of 10 gage electrical wire and cut the outside edge as shown Then cut it in half and glue it on the cockpit edges as shown Glue the IP to the INSIDE of B 1 Print out the Instrument Panel page 35 onto Card Stock cut it out and glue it in place inside the Cockpit www bcair com ...

Page 11: ...age 6 STEP 9 STEP 8 GET AS MUCH OF THE CAN AS POSSIBLE Marry Two Cans from Step 8 together as shown here STEP 10 Cut Template 2 B 2 page 36 from the Two Cans that you married together in Step 9 and form it into a cone Hold it s shape with a piece of tape on the OUTSIDE and glue on the INSIDE as shown B 2 TAB goes on the INSIDE ...

Page 12: ...Side View 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 DO NOT PLUG THE HOLE IN THE CENTER BACK END OF B 1 B 1 B 1 B 2 B 2 Side View Put some glue around the INSIDE rim of B 2 www bcair com ...

Page 13: ...e your Can Opener and cut the Front of the Can out STEP 12 Use your X Acto knife and rough cut the Bottom of the Can off Then use your scissors and clean cut the Front of the Can off STEP 14 Using your fingers as you did in Step 5 Two inside at the Top and One inside at the Bottom PULL the Can Rim into the shape shown This will be B 3 B 3 ...

Page 14: ...3 32 Rod 7 long and bend them as shown below These will be the Wing Spars FWS AWS Enlarge holes A B in B 1 to 3 32 and insert the Rods through them as shown When you have the Rods even and parallel with each other glue the Rods to the INSIDE of B 1 1 3 1 2 3 1 2 A B B A FWS AWS AWS FWS B 1 ...

Page 15: ...F 1 4 back from the leading edge on Top of the WCB as shown STEP 18 Cover the Top of the Wing with a Can Note that the Can covers the WCBAF but does not cover the leading edge of the wing Underside view of the wing Make notches in the Can to bend around the trailing edge of the wing www bcair com ...

Page 16: ...ece of Can 1 wide by 8 long and fold it around the leading edge of the wing as shown Note that the INSIDE of the Can is on the OUTSIDE of the fold Glue the Leading Edge piece of Can to the leading edge of the wing and fold over the wing tip as shown Mark each wing as shown at the right DO NOT put any glue in the 7 8 area shown That is where the wing guns will go 2 5 8 7 8 No Glue here Glue Glue ...

Page 17: ...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 1 16 Tubing 3 4 long 1 8 1 4 3 8 1 2 From the Leading Edge of the Wing www bcair com ...

Page 18: ...them up tight against B 1 until epoxy is dry 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 B 3 B 1 FWS FWS AWS Your plane should now look something like this ...

Page 19: ...nter 1 4 from end of Tail Cone and 1 8 either side of center Cut out TWO 2 HS Template 5 Page 37 and cover with Cans as shown HS HS HS Left HS Top View Left HS Bottom View Completed Left HS Top View Left HS Bottom View Glue Can on the Bottom of HS Glue oversize Can on the Top of HS Corrugation Runs Cut notches in Can and fold Can around edges 1 1 4 1 4 ...

Page 20: ...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 Hold HS s in place until Epoxy Glue is dry Make a 3 32 Hole in the Top Center of the Tail Cone 3 4 from the Back of the Tail Cone Cut VS Template 6 Page 36 from corrugated cardboard VS Corrugation Runs 3 4 ...

Page 21: ...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 The 1 1 2 bend will insert into the VS as shown but not just yet PS PS VS STEP 31 VS Take a piece of 3 32 Rod 1 1 2 long and glue it into the VS as shown VS 3 4 1 1 2 www bcair com ...

Page 22: ... of B 1 and out through the Front of B 3 STEP 33 Take the VS and put some Epoxy Glue on it and the Rod you glued into it Step 31 and slide it onto the PS as shown in Step 30 Put some Epoxy Glue on the Rod end Hold VS in place until Epoxy Glue is dry Pinch the End of the Tail Cone together to match the Rudder of the VS ...

Page 23: ... 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 ET A B C STEP 35 Slide the Joy Stick onto the PS and maneuver it into place within the Cockpit Glue the Joy Stick in place onto the PS PS STEP 36 Take a Pull Tab and glue it to the Back of the Pilot s Seat as the Head Rest The Tab should lean slightly Forward ...

Page 24: ...lear 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 You can get at STEP 37 least two CPC CPC FWS FWS out of one bottle Rough cut the CPC FWS out and then trim them to the proper size ...

Page 25: ... 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 Place the FWS in position and make slits in B 1 where needed Glue the FWS in place Tape off the CPC FWS as shown www bcair com ...

Page 26: ... Glue epoxy the 4 bottle caps together as shown here Wrap the caps 5 6 times with duct tape This will become the Engine Crank Case ECC Place the ECS around the ECC and glue epoxy in place Use a rubber band to hold them in place until the glue epoxy has dried FRONT VIEW Be sure to remove all tape from ECS before gluing them around the ECC STEP 41 Engine OPTIONAL Glue 3 32 Rods or small nails around...

Page 27: ... OPTIONAL METHOD FOR ADDING VALVE PUSH RODS Glue bottle cap with 3 32 Hole in the center over face of engine to finish off push rods 3 32 or 1 16 Rod 1 1 4 long www bcair com ...

Page 28: ...e slightly up and then use your scissors to clean trim the Cowling Engine Cowling Move the Template back into position and cut the Cowl Flap notches Remove the Template and using your Can Opener cut out the Top Front of the Can Using your fingers Pull the Rim of the Can into shape Two fingers inside on top and One finger inside on the Bottom Flair the Cowl Flaps slightly ...

Page 29: ...Cowling and slide the Cowling over the engine and up onto B 3 Hold in place until Glue Epoxy is dry STEP 45 Be sure that the Cowling is aligned properly If you haven t already glue a Bottle Cap over the Front of the Engine to hide the Rod Ends Glue a nut and or washers to the Front of the Engine to add space so the Prop will not rub against the Front of the Cowling ...

Page 30: ...to make One Brace Make Two Braces Take a piece of Can 1 1 2 x 4 and roll it around the Two Braces as shown Glue the Two Braces half way into each end of the Can Cut out Template 10 BTTC page 37 from a piece of Can and shape it into a cone Glue it to one end of the Tank Belly Fuel Tank Radio Antenna Put a Bubble of Hot Glue on the each end of the Tank Glue Two 3 32 Rods 2 long into the Tank as show...

Page 31: ...ter as shown Glue epoxy the two props together I used Two Master Airscrew 5 5 x 4 5 1 2A G F Nylon Propellers from Tower Hobbies Stock LXZ944 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 Rod into it as shown Paint the Bomb if you ...

Page 32: ...btain the rubber wheels for the Thunderbolt from TOWER HOBBIES Tail Wheel 1 2 Sullivan 350 Main Wheels 1 Sullivan 352 STEP 51 1 2 Wheel 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 3 4 3 4 2 1 4 2 1 4 1 1 Wheel 2 Required OPTIONAL RUBBER WHEELS ...

Page 33: ...Glue Tail Wheel Tail Wheel gear door Tem plate 12 page 35 into Tail Cone as shown 2 1 2 STEP 53 STEP 54 Bomb attached to the under side of the wing under the outboard gun Glue on Main Gear Doors Template 13 page 37 1 Tube 2 1 4 Tube 1 1 2 from end of Tail Cone 1 1 4 from end of Tail Cone ...

Page 34: ...and hold in place with an Acorn Nut or Toothpaste Cap OPTIONAL Add Victory Markings and Nose Art as you like Your B C Air Originals Republic P 47D Thunderbolt is now complete B 1 On this plane I used Two props to make One 4 blade prop from Tower Hobbies www towerhobbies com Prop LXZ944 ...

Page 35: ...LATE 1 X X Y Y www bcair com X to X MUST be 8 1 4 X to Y should be 5 When printing out this template Center Bottom of Plane 34 A B DO NOT CUT BLUE LINE To the FRONT of the Plane This edge of Template FLUSH with the Front of the Can C D ...

Page 36: ...rint out on Card Stock Wheel Hubs 35 Bottom Center Of Cowl Front of Cowl DO NOT CUT BLUE LINE TEMPLATE 9 Template 11 BTF Template 12 Double Face Tape on the INSIDE of these Fins Trim Fins to desired shape Tail Wheel Door ...

Page 37: ...www bcair com Top Center of B 2 TAB Glue on the INSIDE Template 2 VS Corrugation Runs 36 TEMPLATE 6 TEMPLATE 7 CPC A B Match upAwith B WHEN CUTTING OUT THESE TEMPLATES CUT IN THE INSIDE OF THE LINES ...

Page 38: ... bcair com Corrugation Runs Corrugation Runs Template 13 Main Landing Gear Door TEMPLATE 3 Template 4 WCBAF TEMPLATE 5 Template 8 WHEN CUTTING OUT THESE TEMPLATES CUT IN THE INSIDE OF THE LINES FWS TEMPLATE 10 BTTC ...

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

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