Every dollar helps!

These manuals are the culmination of more then 10 years of designand 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.

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 asmany of the manuals as they like.

If you enjoy these planes, please help to ensure this site stays on-lineand these airplane manuals remain available for all to enjoy. Any

amount you donate is greatly appreciated.

May God bless you and keep you safe.

Thank You & Enjoy!Wayne

www.bcair.comCopyright © 2010 B. C. Air OriginalsTOP SECRET

Step By Step Construction Plans.32 Pages With Over 100 Full Color Photos showing how to build the

Can be made from most12 or 16 oz Beverage Cans.

Wingspan: 20”Length: 14”Height: 6”

Westland Lysander Mk.I

Welcome to the B. C. Air Originals Squadron.

This booklet contains complete step by step instructions for building the B. C. AirOriginals Westland Lysander Mk I. Before you start building your first plane it issuggested 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 touse to make your first plane. These plans are designed to be used with any 12 or 16oz. beverage can. Always use clean, unscratched and undented cans for the bestlooking planes.

Since the building of these planes requires the cutting of cans and the use of sharptools, CHILDREN SHOULD NEVER ATTEMPT THE CONSTRUCTION OFTHESE PLANES WITHOUT ADULT SUPERVISION AND GUIDANCE.CONSUMER ACCEPTS ALL RESPONSIBILITY FOR ANY INJURY IN-CURRED IN THE BUILDING OF THESE PLANES.

It is not necessary to follow all the building steps in the order presented. Such as, ifyou want to make the Engine, the Wing or the Tail Section first, you can do that andthen set them aside until you need them. However, until you understand the con-struction of these planes, it may be easier to follow the steps in the order listed.Your very first step should be to make a copy of all the templates. All templates aredrawn to scale. Using a sheet of mylar (Clear Plastic) will enable you to re-useyour templates again and again. There is no limit to the number of planes you canbuild with these plans.

We, at B. C. Air Originals, will make every effort to assist you in answering anyquestions you may have about the construction of these planes. Please feel free tocontact us ANY TIME at command@bcairoriginals.com.

Thank you for your interest in the B. C. Air Originals and have FUN!

D. P. (Wayne) Mathis

When you print your manuals be sure that your printer is set on it’s MAXprinting 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 theCans you’re using to make your plane are smaller or larger, then here’swhat you do..... Measure the diameter of your Can and find what percent-age of 2 1/2" it is.... I.e. If your Can measures only 2 1/4" (in diameter)then 2 1/4" is = to 90% of 2 1/2" so you would print out all the templatesat 90% instead of at 100%. If your Can measures 3" (in diameter) then 3"is = to 120% of 2 1/2" so you would print out all of the templates at 120%.etc.Some of these models were originally designed in 1984. Since then thebuilding techniques of these planes has changed over time. I.e. many of theplanes no longer require the use of the wooden former “F-1 & F-2”. Wesimply glue the “B-2’s” onto the BACK (BOTTOM) of the Can “B-1” oruse 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 firstplane, go here > http://www.bcair.com/BT/ < and look over the Builder’sTips. These are building tips sent in from builders all over the world. Theywill help you to make these planes easier and faster. Bookmark this page asit is NOT accessible from the main web site.You can obtain the plastic props used on these planes from yourlocal Hobby Shop or here’s where I get my props on-line > http://www3.towerhobbies.com/cgi-bin/wti0091p?&C=QBC&V=MAS <.Here’s where I get my Wooden Propellers on-line > http://www3.towerhobbies.com/cgi-bin/wti0097p?FVSEARCH=PROPELLERS+++&CATEGORY=QB&MANUFACTURER=TOP&submit=Submit+AdvancedSearch<Any 5-7" prop, with any pitch, will work on these planes.

http://www3.towerhobbies.com/cgi-bin/wti0097p?FVSEARCH=PROPELLERS+++&CATEGORY=QB&MANUFACTURER=TOP&submit=Submit+AdvancedSearch

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.

Small hammer of some kind.Pliers.Flat head screw driver.Hand stapler.Snap (carpet) stapler.Push Pin.Hot glue gun.Awl (old screw driver sharpened to a point).Wire cutter.X-acto knife (hobby knife) (box opener).Scissors & Can Opener.Ruler (straight edge).Felt tip pen (any color).Needle nose pliers.Open end wrench (to fitwhatever size nuts you’ll use).Hand drill (1/4” works fine).Hole saw (2 different sizes - 2 3/4” & 1 5/8”).

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 .

(2 sizes - 1/16” & 3/32”)Hazel Nuts (Acorn Nuts, Cap Nuts, Toothpaste Caps).Screws, Nuts and Bolts.Wire clip (speed nut).

2

Cutting CansThe building of these planes requires that the Tops and/or Bottoms of beverage cans becut 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.

SEE ALL THE BUILDERS TIPS ON-LINE AT > www.bcair.com/BT

What I’ve done here is taken a piece ofboard wood (aprox 12” x 15” x 3/4”) and toit I’ve attached (screw or glue) Two Blocksof wood (2” x 2” x 5”) and Two Rails ofwood (1” x 1” x 10”)

Using a Hose Clamp, I’ve secured myDremal® Tool to the board. The twoguide rails are used to cradle the can.

A cutting wheel is used to cut theBottom and the Top off the Cans.

Again, you can use any other method at your disposal to remove the Tops and Bottoms ofthe cans. Use whatever means you feel most comfortable with.ALWAYS USE PROTECTIVE HAND & EYE GEAR WHEN CUTTING CANS!

In ALL cases, cutthe Bottom off theCan FIRST, thencut the Top off.Get as much of theCan as possible.

Another Way Of Cutting Cans

Once you’ve selected which Cans your plane will be made out of, take one Can and hold it firmly atit’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. The top will normally tare offright 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 yourscissors. Next use a smaller scissor to cut the bottom off the Can.

Use a straight edge, or a papercutter to trim the edges smooth.

Trim Can to 3 5/8” x 8 1/4”

SEE ALL THE BUILDERS TIPS ON-LINE AT > www.bcair.com/BT

Using two hole saws (the larger one is 2 3/4” and the smaller one is 1 5/8”) cut twocircles from any kind of wood that is 3/4” thick. Soft Pine like that used to makewooden pallets works best. These two wooden circles will now become F-1 & F-2.

F-1 F-1F-2 F-2

Using a wood rasp (or similar tool) taper both F-1 & F-2 as shown above. The“Perfect” F-1 and F-2 would have the dimensions shown at right. But they don’thave to be perfect as long as F-1 DOES NOT EXCEED 2 1/2” in diameter. WorkF-1 down to a size (approx. a little less than 2 1/2” in diameter) that will allow it(once wrapped with can B-2 Step # 7 & # 8) to fit inside Can B-1 (Step # 9).

NOTE: You can also use a jigsaw or any other method at your disposalto obtain F-1 & F-2 as long as you end up with the same dimensions.

Cutting Cans

The building of these planes requires that both the Tops and/or Bottoms of beverage cansbe 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 above. TheDremal® is secured to a board with the use of a hose clamp. Two guide rails are used tocradle the can. A cutting wheel is used to cut the Bottom of the can off first, and then theTop is cut off. Again, you can use any other method at your disposal to remove the Topsand Bottoms of the cans. Use whatever means you feel most comfortable with.

The Taper is at 10°

SEE ALL THE BUILDERS TIPS ON-LINE AT > www.bcair.com/BT

STEP # 1

STEP # 2

Once you’ve decided which Cans you’re going to use tomake your plane, cut the Tops and Bottoms off of 17 Cans.Get as much of the Can as possable.

Then, using yourscissors, open all17 Cans up asshown here.

Take ANOTHER Can and cut it 3” down from theTop Rim. Than, using an ordinary Can Opener,cut the Top out as shown here. This will becomeCan B-3.

Take another can and cut ONLY THE BOTTOM off.

STEP # 3

STEP # 4

STEP # 5

STEP # 6

3 5/8”

Remove the Pull Tab and put a 3/32” hole in the center of the little“button” on the Top of this Can. This Can will now become B-1.

3”

STEP # 7

Take one of the Cans that youopened up in Step # 4 and cut theRight Lower Corner off as shownhere.

1 3/4”

3 5/8”

8 1/4”

Then take F-1 (from Step # 1) andstaple it (in the CENTER) of theTOP of the Can as shown below.

F-1

Staple

Bottom of Can

Staple F-2 (from Step # 1) to theCenter of the BOTTOM of the Canas shown below.

StapleF-2

F-2

F-1

(Should look like this.)

STEP # 8

Now roll the Can around F-1 & F-2to form a Cone as shown hereand Stapleto holdin place.

The Can is nowheld in place withFOUR Staples.2 are in F-1 and2 are in F-2.

F-1

F-1

F-2

Trim the Canwhere it over-hangs F-1.

This will nowbecome B-2

B-2

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STEP # 9

Insert B-2 INTO B-1.

B-2B-2

B-1B-1

Staplein three places as shown.

The split in B-2 willbe on the TOP side ofthe Plane. It will becovered later with thePlane’s Back Bone.

Approx.

8”

STEP # 10

Draw a line on Can B-1 where you wantthe TOP CENTER of your plane to be.

B-1

This should line up with the split in B-2.

Trace Template # 1 onto a piece of mylar, cut it out and tape itinto a cylinder matching “X” with “X” and “Y” with “Y”.

Center BOTTOM of Plane

A

A B

B

C

C D

DX Y

X Y

Slide Template # 1 over B-1 as shown above. The Front of theTemplate should be flush with the front (rim) of B-1. The TOPCenter Line that you marked on B-1 should be aligned with theTemplate Ends X & Y. Using your push-pin, make holes “A”where indicated.

TEM

PLAT

E #

1

STEP # 11

Fron

t of

Tem

plat

e

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B-1 B-2

WH

EN P

RIN

TIN

G O

UT

THIS

TEM

PLAT

E X

TO

X (&

Y T

O Y

) MU

ST M

EASU

RE

8 1/

4”.

STEP # 12

With Template # 1still in place and thePuch Pins still inHoles A, make HolesB, C & D whereindicated.

A

C

D..

Bottom of Plane Top of Plane

STEP # 13

. .Take Four pieces of corrrugated cardboard1” x 2 1/2” and glue them on top of each other.Then glue Two pieces of 3/32” Rod 3/4” longhalf way into them as shown below. 1”

2 1/2”

5/8” 5/8”

1/2”

1/2”

STEP # 14Remove Template # 1 from the Cans andenlarge Holes C and D to 3/32”. Insert thetwo rods, in the cardboard, into Holes C &D in B-1 and glue the cardboard to thetop of the Can.

Also glue the rods to the INSIDE ofthe Can, working through the drinkhole in the front of the Can.

B-1

Hole CHole D

You can use two-sided tapeto stick them together.

2 1/2”

3 1/2”

1”1 1/4” 1 1/4”

Score LinesDO NOT CUT

TEMPLATE # 2

Cut Template # 2 (CPC)from one of the Cans youopened up in Step # 4 andbend it into shape as shownbelow.

STEP # 15

STEP # 16

Place Cockpit Cabin in positionand mark B-1 where Tab Slits needto be made.Front of Template # 2 should beflush with rim of Can as shown.

B-1

Make Slits in B-1

Tabs

STEP # 17Insert CockpitCabin Tabs intotheir slits, in B-1,and glue in place.

Insert a piece ofcardboard, 1” x2”, on either sideof the 4 stacks ofcardboard andglue in place.

B-1

Push cardboard inflush with the 4 stacks.

CPC CPC

CPC

CPC

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TEMPLATE # 3

TEMPLATE # 4

STEP # 18

= Score LinesDO NOT CUT.

Cut ONE Template # 3 from oneof the Cans you opened up inStep # 4.

Cut TWO Template # 4 from twoCans from Step # 4.

Be sure to FLIPTemplate # 4 to getthe correspondingpattern.

HS (Bottom)

HS (Bottom)

Tail Cone

VS

HS (Top)

Tail Cone

STEP # 19

VS VS

VS

VS VSCB

VSCB

HSHS

HS

HSHS

VS Left Side & HS Left Side Top VS Right Side & HS Right Side Top

Staple the two VSpatterns together asshown.

Staples

Staples

STEP # 20 Cut a piece of cardboard (VSCB) to fit INSIDE VS.

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STEP # 21

HS Right & Left Sides Bottom

Staple Template # 4 to the twoTemplates # 3 as shown.

Staple the BACK of the TemplatesFIRST.

Cut a piece of cardboard (HSCB)and insert it into the tail section.

Complete stapling of the tailsection all the way around. Whencomplete you should have 21Staples in the Tail Section.

HSCB

HSCB

HS

HSHSRight Side Top

Right Side Top

Staple the BACK of the Templates FIRST.

Cut a piece of cardboard (HSCB)and insert it into the tail section.

STEP # 22Take a piece of 3/32” Rod, 18” long,and bend a 1” Hook at one end.

This will become the PS.

Insert the Rod into the Tail Sectionand hook the HSCB.

Insert the PS through the pilot holein F-2, through the pilot hole in F-1,and out through the 3/32” hole thatyou put in the little button on thefront of B-1.

Draw the tail section up OVER theback end of B-2 and hold the PS inplace with a Wire Clip as shown.

The small part of the Hookgoes UNDER the HSCB.

B-2

B-2

PS

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F-2

Stack 6 or 7 Pull Tabs, hold in place witha strip of tape, and glue/epoxy themtogether. Make 7 stacks of Tabs.These will become the Engine Cylinders (ECS).

Take 4 bottle caps and puta 3/32” hole in the center ofeach cap. Glue/epoxy 2caps together as shown.

.

.

.

Glue/epoxy the 4 bottlecaps together as shownhere.

Wrap the caps 5-6times with duct tape.

This willbecomethe EngineCrankCase(ECC).

Place the ECS around the ECC andglue/epoxy in place. Use a rubberband to hold them in place until theglue/epoxyhas dried.

FRONT VIEW

Be sure toremove alltape fromECS beforegluing themaround theECC.

STEP # 23

* OPTIONAL *Glue 3/32” Rods,or small nails,around the engineto represent ValvePush Rods.

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STEP # 24Take FOUR additional Bottle Caps and glue them together as you did to makethe ECC. (Be sure to put a 3/32” hole in the center of each Cap.) Slide themonto the PS and glue them to the front of B-1 Can. Then slide the Engineassembly onto the PS and glue the Back of the Engine to the Caps.

B-1

B-1

B-1

B-1

B-2

B-3

B-3

Glue to Can

Glue to Caps

STEP # 25

Your Plane should now look like this.

Take Can B-3 (from Step # 6) and putsome glue on the INSIDE, about 1/4”from the BACK End, and slide it overthe engine and onto the Front of B-1.

Can should rest againstengine valve rods (or cylindersif your engine does not have thevalve rods).

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STEP # 26

TEMPLATE # 5

Cut Template # 5 (BB) from one of the Cans fromStep 4 and place onto the Back of B-2. Mark B-2where the Tab Slits need to be made. Make theSlits in B-2 and glue BB in place.

BB

BB BB

B-2 B-2Plane’s Right Side Plane’s Left Side

STEP # 27

TEMPLATE # 6

RW

RW

RW

Cut Template # 6 (RW) from oneof the Cans from Step # 4 and placeit in position on the Back of BB andup against CPC as shown.

CPC

CPC

B-1

B-1

Make Slits in B-1where needed for theTabs on RW.

Put some glue on theINSIDE of the RWTabs and insert theminto the Slits in B-1.

Hold RW in place witha strip of tape until glueis dry.

BB

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STEP # 28

Take a piece of CorrugatedCardboard 3” x 20” and cutit to the shape shown at theLeft.

1 1/2” 1 1/2”

7”

6 1/2”

3”

3 1/2”

1/2”

2 1/2”

3”

3 1/2”

7”

6 1/2”

1 1/2” 1 1/2”

<---

Cor

ruga

tion

Run

s ---

>

Using strips of 1” wideCorrugated Cardboard,add four pieces to theTop of the Wing Card-board as shown at theRight. (You can stickthem down with double-face tape.) Then trim theWing Cardboard asshown.

WC

BW

CB

AF

STEP # 29Cover the UNDERSIDEof the Wing FIRST. Use Double-Face Tape to stick Cans to WCB

Work from the Center out.

Can is Flush withLeading Edge ofWCB.

This is the UNDERSIDE of WCB

1 Can 1/2 Can

1/2 Can

1/2 Can 1/2 Can

1/2 Can 1/2 Can

1/2 Can 1/2 Can

1 Can

1 Can 1 Can

1 Can 1 Can

1 Can 1 Can

1/2 Can 1/2 Can

TOP Side of WCB

WCBAF

Trim Cans

UNDERSIDE OF WING

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STEP # 30

WCBAFWCBAF

WCB

1/2 Can

1/2 Can

1 Can

1/2 Can

1 Can 1 Can1/2 Can1/2 Can

Staples Staples Staples

TRACE TEMPLATE # 7 ONTO WING BEFORE STAPLING.

TRIM WING AFTER STAPLING.

Cover the TOP of WCB with Cans. Use double face tape on WCBAF tostick Cans to wing. Fold the Can over the Leading Edge of the WCB 1/4”.

TEMPLATE #

7W

ing

Flip Template to get Left Wing.

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STEP # 31

Take a flat head nail and stick it through the TopSide of the wing. Poke several (8-10) holes in thecenter area of the UNDER side of the wing. Alsopoke several holes in the Top of the CPC. (This isto give the glue something to hold on to.)

CPC

Glue the Wing to the Top of CPC.

CPC

STEP # 32

Cut Template # 8 (FCP) from Can. Place inposition and mark B-3 where Slits need to bemade. Tuck rear Tab UNDER the Back Endof the Wing. Use tape to hold in position.Glue FCP in place.

TAB

Template # 8FCP

B-3 B-3

FCP

FCPFCP

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STEP # 33

TEMPLATE # 9

FWS FWS

Cut Template # 9 from Can and glue in place.

STEP # 34

Use plastic tape tooutline the windows onthe Cockpit, Cabin andRear Window.

STEP # 35

1 3/4”

2” 2”

1” 1”

3/4” 3/4”2” 2”

1 3/4”

MLG

LGS

Take a piece of 3/32” Rod, 9 1/4” long, and bend it as shown for the MLG.Take a piece of 3/32” Rod, 5 3/4” long, and bend it as shown for the LGS.Take a piece of 3/32” Rod, 3” long, and bend it as shown for the TW.

TW2”

1/2”

ET 5356 Aluminum Rod

STEP # 36

Take 8 Ring Electrical Terminals, (ET)size 4-6 Stud, and remove the plasticinsulator.

Spread the ET so that a 3/32” Rod willslide easily into it.

For this plane I used 5356 Aluminum Rodbut 3/32” Round Rod will also work.

Cut Two pieces of Rod 5” long and Twopieces of Rod 5 3/8” long. These will bethe Wing Struts (WS).

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STEP # 37 Landing Gear.Insert the MLG through Holes A in B-1.

Insert the LGS through Holes B in B-1.

MLGLGS

Holes A

Holes B

B-1 B-3

Slide a ET onto both the MLGand LGS as shown.

ET

LGS

MLG

Tape a piece of cardboardbetween the MLG and theLGS as shown.

Repeat on other side.

STEP # 38

Insert the WingStruts into theET’s on thelanding gearand epoxy/gluethem in place.

Glue/epoxy theMLG and theLGS to thecardboard.

STEP # 39

5 3/8” Rod

5” Rod

Make Slits in the underside of the wing at the ends of the WS Rods.Glue ET’s into wing Slits.Insert WS Rod ends into wing ET’s and glue in place.

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STEP # 40

Making the Wheel Pants

Cut TWO Template # 10 from Cans.

Template # 10

AB

C

AB

C

C

Fold B behind CFold A over BTape or glue in place.

Inside View

Outside View

D E

F G

Tail Tail

Making the Wheel Pants continued

Fold C downand over A &B on the inside.

C

C

C

AB

OutsideView

Inside ViewFold D over E.

DED

EDF

G

G

Tail

Tape the Tailstogether.

Fold F over Dand G over F

Make Two.

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Cut out a half circle1 1/2” in diameteron the OUTSIDE ofeach wheel pant asshown here.

Put a 3/32” hole in theTop of each Wheel Pantand insert the MLG.

Glue/epoxy the WheelPants to the MLG.

STEP # 41

STEP # 42

STEP # 43 Take 4 Bottle Caps. Glue Two together tomake one wheel. Paint Caps Black. Cut outand paste wheel rims at right to the Caps.

STEP # 45 Cover MLG and LGS with Cans as you did the wing.

Mount Wheels and holdin place with Acorn Nut.

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STEP # 44

Put 3/32” hole in the UNDERSIDE of the TailCone (about 1” from the end) and insert TWinto hole, through HSCB and into VSCB.

Fill hole in the back of the Tail Cone with HotGlue.

Your B. C. Air OriginalsWestland Lysander Mk I isnow complete.

If you use a plastic, or wooden, model airplane prop you may find that the hole in the centerof the prop is larger than the PS. To reduce the size of that hole you can use a 3/32” AnchorBolt glued/epoxied into the back of the prop.

FLATTEN the three spikesbefore securing to the prop.

STEP # 46Install the Prop onto the PS and secure in place with a nutand wire clip or some other means. Cut off excess PSand cap PS with Acorn Nut.

Be sure the Prop will spin freely.

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E-mail me a photo of yourPlane and I’ll put it in theBuilders Gallery.

On this plane I used a prop from Tower Hobbies (www.towerhobbies.com). Prop # LXFTE7