Here are some pics of my Zero wing build.
This calls for all the usual supplies, xacto knife, scoring tool, hot glue, mat, straight edge and a couple other odds and ends.
Cutting the cans consistently is easily done by buzzing the ends off using a dremel tool.
I typically cut through the ingredients chart as shown. I use the upper dark line as a point on either end. This is very useful when the top edge needs to be cleaned up.
The first step in constructing the lower half of the wing is to cut and smooth out 8 cans. Gently roll in the opposite direction the can wants to roll. Next, make a straight edge along the top of each can using the top of the ingredients chart for reference.
Once trimmed, shingle them in long skinny line. I typically overlap approximately 1/8"-3/16" . Tape each seam entirely.
After taping all sheets, fold the first sheet back and apply heavy bead of hot glue. Repeat until all seams are glued.
Next, tape pattern in place and mark each end of the score with a scoring tool. Once done, flip over and connect the dots using a scoring tool. The scores help the wing stay flat. Once scores are done, the wing my be cut out.
Once this is done, mark wing location for supports and then cut wing out using template
Cut two folded wing supports for each side and glue in place using marks as guide
Add additional glue at all seams