How to Build a 1989 Batman Batwing Replica From Soda Cans

We made this 1989 Batwing scale replica from 24 beverage cans, 110lb card stock, and custom templates to perfectly capture that aggressive, cinematic silhouette. Check out the provided Youtube build video to see the COMPLETE scratch-built aluminum model process: https://youtu.be/c38EwZd0qHU

After more than twenty years of scratch-building miniature aircraft and competing in scale modeling events, I've learned that bridging the gap between simple recycling and high-detail technical crafting all comes down to precise structural planning and real, manual crafting techniques. In a landscape often flooded with digital or AI-generated concepts, this DIY upcycled craft project puts the focus entirely back on physical materials and authentic human skill. For this specific build, I utilized 24 Pepsi cans—leveraging the black exterior for the primary fuselage and contrasting silver aluminum for the canopy window overlays to create a realistic glass effect without needing clear plastics.

What You Will Learn in This Guide Because my companion video focuses entirely on demonstrating the live, hands-on build process, this Instructable is designed to be your definitive technical resource. I will walk you through the exact steps needed to safely prep your metal and assemble the core components using specialized soda can airplane plans and templates, including:

1. The Main Body Plate: The foundational silhouette that anchors the entire wing planform of this pop-culture replica.
2. Fuselage Side Panels: The vital outer skins that seamlessly connect the upper and lower fuselage sections of your custom scale model.
3. Upper Wing Louvers & Airbrakes: The intricate, mechanical surface details that give the Batwing its functional, heavy-machinery aesthetic.

Grab your hobby knife, clear off your cutting mat, and let's bring a piece of Gotham directly to your workbench.

Supplies:

1. '89 Batman Soda Can Batwing Build Templates (Provided in the downloads section)
2. 24 Clean, undented aluminum beverage cans (Pepsi cans are ideal to utilize the natural black and silver finish)
3. Heavyweight 110lb Card Stock
4. Loctite Super Glue (Both Gel and Liquid variants)
5. 5-inch precision craft scissors (Essential for detailed aluminum cutting)
6. Hobby knife or X-acto blade
7. Metal ruler or straight edge
8. 2mm EVA Craft Foam (Provides the core structural support for the wing base)
9. Fine-tipped Sharpie marker (For tracing templates onto the dark metal)
10. Single or dual-bladed can slicing tool (Highly recommended to safely and quickly break down the cans into flat, workable aluminum sheets)

Step 1: Constructing the Batwing Central Wing Base

Before you begin, refer to the Can Prep Guide included in your digital downloads. You will need to create extended, flattened sheets of recycled aluminum to accommodate the large size of the base templates. (Using a single or dual-bladed can slicing tool makes breaking down the cans into workable sheets much safer and faster).

1. Trace and Cut the Aluminum (Photos 1-5): Using a fine-tipped Sharpie and the provided Batwing templates, trace and cut out Central Wing Base Part A and Part B from your extended soda can sheets.
2. Reinforce the Panels (Photos 6-9): Once both aluminum wing base pieces are cut out, reinforce the inside (unpainted) surface of each piece by gluing down additional flat soda can material. Continue applying super glue and extra scrap metal until the entire inner surface of both pieces is completely covered and structurally strengthened.
3. Cut the Foam Core (Photos 10-13): Using the same wing base template, trace and cut out a single identical piece from 2mm EVA craft foam. This will act as the rigid center of the custom scale model's wing assembly.
4. Assemble the Metal Sandwich (Photos 14-18): Glue the 2mm EVA foam directly to the reinforced inside surface of one of your aluminum wing base pieces. Finally, carefully align and glue the second aluminum wing base over the top of the foam, cleanly sandwiching the EVA core between the two recycled metal layers.

Builder's Note: For a closer look at how to properly align and reinforce these layers, be sure to reference the companion YouTube video for a real-time demonstration of this exact step!

Step 2: Assembling the Batwing Upper Fuselage

1. Trace, Cut, and Fold the Upper Fuselage (Photos 1-5): Use the provided Batwing template to trace and cut out the Upper Fuselage piece from your soda can sheets. As seen in photo 4, ensure you cut the nose section exactly as indicated on both lines using a hobby knife or precision scissors. Once cut, fold the nose piece downward as indicated (Photo 5).
2. Reinforce the Fuselage (Photos 6-8): Reinforce the inside (unpainted) surface of the upper fuselage piece by gluing down additional flat recycled aluminum. Continue this until the entire inner surface is completely covered and strengthened to support the scale model.
3. Fabricate 'L' Brackets (Photos 14-17): Cut small, rectangular strips of scrap can material about 1cm in length. Use a metal ruler or straight edge to bend each strip precisely at a 90-degree angle, forming tiny 'L' shaped brackets. (These brackets are the secret to assembling scratch-built aluminum models without visible, messy seams).
4. Attach the Long Side Panels (Photos 9-13, 18-22): Trace and cut out the Longer Upper Fuselage Side Panel pieces and make folds along the solid lines to match the outer contour. Apply super glue to attach your tiny 'L' brackets along the outer edge of one side of the upper fuselage (Photo 17). Next, glue the folded aluminum side panel directly to these brackets (Photos 18-20). Repeat this entire process for the opposite side (Photos 21-22).
5. Attach the Short Rear Panels (Photos 23-33): Trace, cut, and fold the Shorter Upper Fuselage Side Panel pieces. Glue a new set of 'L' brackets along the outer edge of the rear of the upper fuselage (Photos 23-27). Glue the shorter soda can piece to these brackets (Photos 28-33) and repeat for the opposite side.
6. Attach the Nose Panels (Photos 34-38): Trace, cut, and fold the Nose Side Panel pieces along the solid lines to match the shape of the nose. Line the outer edge of the nose with 'L' brackets (Photos 34-35). Glue the nose side panel piece to the brackets, repeating for the opposite inner nose edge until the front of your Batwing replica is complete (Photos 36-38).
7. Mount to the Central Wing Base (Photos 39-45): Create longer 'L' brackets and glue them securely along the inside bottom edges of the completed upper fuselage assembly (Photos 39-42). We will use these to affix the piece to the central wing base. Finally, align and glue the upper fuselage into its final position on the base assembly (Photos 43-45).

Step 3: Shaping the Batwing Lower Fuselage from Aluminum Sheets

1. Trace, Cut, and Fold the Lower Fuselage (Photos 1-5): Use the provided Batwing template to trace and cut out the Lower Fuselage piece from your flattened soda can sheets (Photos 1-3). Make the cuts along the two solid lines at the nose piece exactly as indicated in photo 4 using your precision scissors, then fold the nose section downward (Photo 5).
2. Reinforce the Aluminum Fuselage (Photos 6-7): Reinforce the unpainted inside surface of the lower fuselage by applying super glue and additional flat recycled aluminum material. Continue this until the entire inner surface is completely covered and structurally strengthened to handle the rest of the build.
3. Attach the Long Side Panels (Photos 8-18): Use the template to trace and cut out the Longer Lower Fuselage Side Panel pieces. Make a single bend at the solid line to shape each aluminum panel to the outer edge of the lower fuselage (Photos 8-10). Glue 1cm 'L' brackets (the scrap metal brackets introduced in Step 2) along the outer edge of the lower fuselage (Photo 11), then glue the side panel directly to those brackets (Photos 12-15). Repeat this entire process for the opposite side (Photos 16-18).
4. Attach the Short Rear Panels (Photos 19-28): Trace and cut out the Shorter Lower Fuselage Side Panel pieces from your prepped beverage cans, making folds along the solid lines to match the rear shape of the fuselage. Line the outer edge of the rear of the lower fuselage with 1cm 'L' brackets (Photos 19-21), then glue the shorter side panel to them (Photos 22-24). Repeat these steps for the opposite side (Photos 25-28).
5. Attach the Nose Panels (Photos 29-33): Trace and cut out the Nose Side Panel pieces, folding them along the solid lines to match the iconic shape of the Batwing replica's nose (Photos 29-30). Line the outer edge of the nose area with 1cm 'L' brackets and glue the nose panel to the brackets (Photos 31-32). Repeat for the opposite nose edge (Photo 33).
6. Mount to the Central Wing Base (Photos 34-39): Fabricate slightly wider 'L' brackets from scrap metal sheets and glue them to the underside of the completed lower fuselage assembly so that they sit flush with the side panels (Photos 34-36). Finally, use these brackets to firmly glue the lower fuselage directly to the bottom of the central wing base, completing the main body of your custom pop-culture replica (Photos 37-39).

Step 4: Crafting the Batwing Canopy and Aluminum Window Overlays

1. Trace and Cut the Canopy Frame (Photos 1-4): Use the provided Batwing template to trace and cut out the Canopy Frame from your darker, prepped soda can sheets.
2. Form the Glue Tabs (Photo 5): Make sure to carefully cut along all 6 of the solid lines indicated on the canopy template using a hobby knife or precision scissors to create the internal glue tabs.
3. Shape the Aluminum Canopy (Photos 6-8): To help form the curved shape of the canopy, apply super glue to each of the six tabs with a slight overlap. The completed recycled metal piece should look as shown in photo 8.
4. Attach the Window Overlays (Photos 9-12): Use the templates provided to cut out the Canopy Window Overlays from a contrasting color can (like silver, or blue beverage cans). Glue these directly to the top of the completed canopy piece to create the appearance of realistic glass without needing clear plastics on your custom scale model.
5. Reinforce the Base (Photos 13-16): Glue thin, narrow strips of 2mm EVA craft foam around the inside bottom edge of the canopy. This creates a wider, more secure gluing surface for mounting the metal directly to the body.
6. Mount to the Fuselage (Photos 17-19): Once the foam reinforcement is set, carefully align and glue the completed canopy to the top of the upper fuselage. The completed 1989 Batwing replica assembly should look as shown in photo 19.

Step 5: Building and Mounting the Batwing Missile Pods

1. Trace and Cut the Pods (Photos 1-2): Use the provided Batwing templates to trace and cut out the main Missile Pod pieces from your prepared soda can sheets.
2. Reinforce the Inside Surface (Photos 3-4): Line the inside surface of each piece with flat recycled aluminum material so that the shiny (unpainted) side is completely covered and structurally strengthened.
3. Create the Foam Core (Photos 5-7): Trace and cut out THREE identical missile pod pieces from your 2mm EVA craft foam. Glue all three foam pieces together into a single, thick stack to give the pod realistic bulk. Apply super glue to attach this foam stack directly to the reinforced inside surface of the metal pod piece.
4. Attach the Aluminum Side Skins (Photos 8-13): Use the template provided to trace and cut out the Missile Pod Side Skin. Apply glue to the exposed side of the foam stack (Photo 10), then attach the soda can side skin directly over the foam (Photos 11-12) to cleanly close up the pod. The completed assembly for your scratch-built model should look as shown in photo 13. Repeat this process to complete the second pod.
5. Mount to the Fuselage (Photos 14-17): Now we are ready to attach the completed missile pods on either side of the canopy. Dab super glue onto the exposed foam underside (Photo 14) and mount the pods securely into their final positions on the upper fuselage of your 1989 Batwing replica, as indicated in photos 15-17.

Step 6: Assembling the Batwing Upper Vertical Stabilizers

1. Trace and Cut the Metal (Photos 1-2): Use the provided Batwing template to trace and cut out the Upper Vertical Stabilizer pieces from your prepped soda can sheets. Note that you will need both a left and right (mirrored) piece for each completed stabilizer.
2. Cut the Foam Core (Photo 3): Use the same template to trace and cut out corresponding stabilizer pieces from the 2mm EVA craft foam.
3. Reinforce the Inside Surface (Photos 5-6): Reinforce the inside (unpainted) surface of each aluminum stabilizer piece by gluing down additional flat recycled aluminum until the shiny surface is completely covered and structurally strengthened.
4. Assemble the Metal Sandwich (Photos 7-10): Apply super glue to attach the EVA foam stabilizer core directly to the reinforced inside surface of one of the aluminum pieces. Next, carefully align and glue the corresponding mirrored aluminum piece over the top of the foam, cleanly sandwiching the EVA core between the two recycled metal layers. Repeat these steps to construct the second stabilizer assembly for your custom scale model.
5. Mount to the Fuselage (Photos 11-14): Once both stabilizers are assembled and dry, glue them firmly into their final positions on either side of the upper fuselage of your 1989 Batwing replica, as indicated in the photos.

Step 7: Building the Lower Vertical Stabilizers and Final Batwing Details

1. Trace and Cut the Metal (Photos 1-2): Use the provided Batwing templates to trace and cut out the Lower Vertical Stabilizers from your prepared soda can sheets. Keep in mind that you will need a left and right (mirrored) side piece for each stabilizer.
2. Cut the Foam Core (Photos 3-4): Use the template to trace and cut out a corresponding stabilizer core from the 2mm EVA craft foam.
3. Reinforce the Inside Surface (Photos 5-6): Reinforce the inside (unpainted) surface of each half of the aluminum stabilizer by gluing down additional flat recycled aluminum until the shiny surface is completely covered and structurally strengthened.
4. Assemble the Metal Sandwich (Photos 7-9): Apply super glue to attach the EVA foam stabilizer core directly to the reinforced inside surface of one of the aluminum pieces. Then, carefully align and glue the remaining mirrored aluminum piece over the top. Repeat these steps to complete the second stabilizer assembly for your scratch-built model.
5. Construct and Attach the Base Ovals (Photos 10-12): Cut out a pair of aluminum ovals and their corresponding EVA foam pieces. Glue the foam directly to the inside surface of the metal ovals. Finally, mount and glue the completed stabilizers to the top of each reinforced oval base.
6. Mount to the Lower Fuselage (Photos 13-14): Carefully flip the main model upside down and glue each of the lower vertical stabilizers securely to the back strip of the lower fuselage, exactly as indicated in the photos.
7. Add Final Surface Details (Photo 15): To finish the build, glue the intricate Airbrakes and the Upper Wing Louvers into their designated positions on the upper wing surface of your custom scale model. Reference both the provided photos and the layout on the central wing base template for precise placement.

Your scratch-built aluminum 1989 Batman Batwing is now complete!