How to Make a DIY Homemade Soda Can Airplane With Recycled Aluminum Cans

We made this cool DIY WW2 soda can airplane Japanese Zero using recycled aluminum cans and a 3D printed propeller in just a few hours time. Now we'll show you how to make one yourself!

24-36 clean, undented aluminum cans

Straight edge or ruler

Ultra fine point Sharpie

Loctite Super Glue Gel (or other brand)

5 inch precision scissors

Hobby knife

Craft Foam

Clear Vinyl for canopy

Wooden dowel or other rounding tool

WW2 Soda Can Airplane templates

3D printer to make the propeller (optional)

You'll need at least 24 clean, undented soda cans. First, shell your cans by cutting off the top and the bottom. Also cut off an eighth of an inch along the top and bottom edges until the cans look like the sheets shown in the last photo.

Use the template provided to trace and cut out the fuselage. Make sure to cut out the slits at the rear of the fuselage to insert the stabilizer in later steps. Use a ruler or straight edge to fold all of the glue tabs and the wing root fairings as shown. Next, use a wooden dowel or similar rounding tool to round the fuselage into shape as shown. Finally, glue along the rear fuselage tab as shown in the 9th photo. Glue along the two tabs at nose of the fuselage as shown in the last two photos to complete the piece.

Use the template provided to trace and cut a top and bottom horizontal stabilizer out of can. Trim the edges on the bottom piece so it fits inside the top piece, then glue it to the underside of the top piece as shown. Slide the completed piece through the two slits at the rear of the fuselage that we cut out in the previous step. Repeat the previous steps to create another can stabilizer piece that we'll need for the next step.

Trace and cut out a stabilizer piece out of craft foam. Cut the piece in half and trim each side to fit the underside of the can stabilizer already inserted through the fuselage. Glue the foam stabilizers to the bottom of both sides of the can stabilizer. Take the second can stabilizer we made in the previous step, cut it in half, trim the pieces to fit and glue them over the foam stabilizer pieces as shown.

Use the template provided to trace and cut out the vertical tail. You will need a left and right piece from can as well as a corresponding piece out of craft foam. Cut out reinforcing can tail pieces and glue them to the inside surface of the left and right can tail piece. Next, glue the two can tail pieces to either side of the foam piece. Finally glue the vertical tail into position on the fuselage as shown.

Use the templates provided trace and cut out a top and bottom main wing piece out of can as shown. Next, use the templates to cut out reinforcing can pieces and glue them to the inside surface of each wing piece until the can surface is sufficiently covered. Also cut a wing piece out of the craft foam as well. Cut the foam wing piece in half and glue each half to the inside surface of the bottom can wing piece. Make sure the top can wing piece has a light dihedral bend to it as shown, then glue it over the foam as indicated.

Test fit the wing to the opening on the bottom of the fuselage. You may need to trim the tab on rear edge of wing to fit the opening, so make sure to trim just enough until you achieve a snug fit. Dab glue onto the wing root fairings and the front lip on the underside of the fuselage, then insert the wing and hold into position until the glue sets. Further secure the wings in place with strips of can inserted through the canopy opening and glue them where the wings and fuselage meet.

Use the templates provided to trace and cut out the two nose cowling pieces and the nose disc (top and bottom piece). If you don't have a 3D printer to print your own propeller from the included STL file, you will need to use the propeller and spinner templates to make you own propeller out of can. Roll each cowling piece and glue along the glue tab. Glue the top and bottom nose disc pieces together. Next, bend in the glue tabs at the front of the main nose cowling piece and glue the nose disc directly onto the tabs. Glue the smaller cowling piece over the nose disc. Drill a hole through the nose disc as well as the propeller. Insert a finishing nail through the hole in nose disc, dab glue onto it then press the propeller over the nail. Glue the completed nose cowling/propeller assembly onto the front of the fuselage as shown. If you made your prop and spinner out of can, use a small nut and bolt to secure it instead of a finishing nail.

Use the template provided to trace and cut out the canopy from clear vinyl. Next, use the canopy template to trace and cut out the canopy frame from can. Use a hobby knife to cut out and remove all of the frame windows. Glue the three completed can frame pieces to the top of the clear vinyl canopy piece. Next, dab glue onto each of the four canopy glue tabs one at a time to form the canopy piece. Finally, glue the canopy to the top of the fuselage as shown.

Use the template provided to trace and cut out the scoop. Fold the glue tabs in and glue it to the bottom of the fuselage as shown. Take some red and white can and use it to fashion some insignias for your DIY WW2 soda can airplane model. Glue them into position as shown on the wings and the sides of the fuselage. Your model is now complete!