I know you can say " happy as can be," but can you us any adjective before "as can be"?
Can I say " I was as American as can be"? or " He was as excited as can be"?
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You can only use the construction with classifying, absolute and extreme adjectives if you're being tongue-in-cheek or whimsical.
*/?'The bridge is as wooden as can be.'
*/?'The weapon is as nuclear as can be.'
*/?'The event is as annual as can be.'
*/?'He was as dead as could be.'
*/?'It is as microscopic as can be.'
But often non-gradable adjectives are treated as gradable with secondary senses:
as American / alive / full as can be.