Just for Fun: Can air
In which the author attempts to build his first ‘airplane’
Transforming cans
The key to mentally and emotionally surviving such a strange period in our history is to stay active, exercise, and continue to challenge yourself. So began my interest in building a model airplane.
Like many pilots I’m smitten with the idea of building my own airplane. This, despite a lack of tools, skills, or patience to undertake such an endeavor. It might be part of the reason I’ve always enjoyed seeing airplane models made from beer and soda cans. B.C. Air Originals is, well, the original source of plans for can models of everything from a Cessna 172 to a Star Wars TIE Fighter. Owner Wayne Mathis began making the plans in 1984 after a flying friend bet him he couldn’t make a good-looking airplane out of a can. Many times I’ve considered spending the $10 to get a set of his plans. Alas, I’m too cheap, not to mention intimidated, to pony up the $10.
In response to the pandemic, Mathis decided to give back to the community, and is now offering for free his entire stock of more than 50 plans. This is a price I can get behind, so I perused the website and decided to build a T–6.
For weeks I dutifully drank the beer and collected the empty cans. I kept a few cardboard boxes, went to the store for a bit of wire, printed out the plans, and finally overcame my insecurities and made a commitment to start building. Deadlines will do that to you.
It began well. I gathered a few basic tools and the materials, and sat down alone outside on a nice day to finally get started. Although I had wanted to get my kids involved, something in the back of my mind told me that it wouldn’t be a good idea, and I was right. Not only is the construction time-consuming, it’s also potentially ouchy for little fingers.
Like putting together a piece of furniture from Ikea, the plans are easy to understand, and immediately lull you into a false sense of confidence. Step 1: Pull the tab off the top of a can and cut off the bottom. (I can do that!) Step 2: Cut a different can about 2.5 inches from the top. (Why had I waited so long to do this when it is so easy?) Step 3: Pull the tabs off 13 cans and cut off the tops and bottoms of each. (Ugh.) Momentum lost.
I knew it was time to stop building for the day when I glued the carboard wing doubler onto the wrong side of the wing. This was not entirely surprising given my notorious history of mounting shelves upside down on Ikea furniture.
Mathis said more than 5,000 people have built airplanes from his plans, and the photos on his website show many are quite skilled at doing so. They work tirelessly to line up the cans like some professional advertising wrap. Suffice to say, my photos will not be going on the website. No one wants to see pictures of upside-down wings and a pile of “mistake” cans.
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Tips for building
Can airplane builders love to offer helpful tips, and dozens of useful pieces of information on the B.C. Air website can save you time and frustration, and result in a better model. Here are a few things I learned:
Stay organized. You’ll begin the build by making different parts of the model before it comes together into one piece. If you don’t stay organized you will lose pieces, accidentally throw away others, and generally get frustrated.
Be creative. You won’t be applying for an airworthiness certificate when this is over, so don’t worry about substituting materials or changing methods.
Be strategic about involving kids. The cans often have sharp edges. And the beginning can be time-consuming. Read the plans thoroughly and be thoughtful about when to involve kids in the process.
Drink up! You’re going to want extra cans.
Take your time. I began with speed and efficiency in mind, realizing later that the entire point of this exercise is to slow down and enjoy the experience.
Kitchen shears are amazing. A good pair of kitchen shears makes many of the tasks quick and easy.
Don’t buy expensive tools. Although the plans describe a jig with a Dremel tool that would make can cutting quick and easy, there’s no need to buy expensive tools solely for this purpose. Some glue, cardboard, kitchen shears, and a stapler can do most of the work.
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