THE CAVALIER CONSTRUCTION PAGE
A 102.5 is a homebuilt-type plane. It has a wooden airframe covered with plywood and fabric. It's basically a 2+2 seater (ie. there's room for 2 children in the back or some extra luggage if you prefer up to around 55kg). Cavaliers with an engine of about 125HP will cruise along at around 130mph (around 210kmph).
Check out the progress of my Cavalier by clicking on the links below
Tail Section
Mid Section
Canopy & Firewall
Tip Tank plug under construction
I have joined several pieces of 10mm X 75mm Douglas Fir (Oregon) to create some spar laminations of suitable lengths. The longest laminations are 7.5m and as wasn't able to get full length timber, I was faced with "scarfing" shorter pieces together to make up the length. Some photos of the joints and the over-head planer I used to prepare them can be seen further down on this page.
Below are some photos of the construction of the top flange of a Cavalier 102 wing spar - I can hardly wait to get the spar ready to start attaching wing ribs to it!
Glue being applied to spar laminations
Laminations glued & screwed ... well, clamped anyway!
Spar laminations forced down to top of spar bench
Another view of the clamped spar flange
Overhead planer for creating scarf joints
Scarfed spar lamination
One important lesson learned - there's no such thing as too many clamps!
Here are the long awaited photos of the lower spar flange and some other surprises! These photos were taken during December 2000 and January 2001.
Lower spar flange glued and clamped against the jig
Spar laminations forced down to top of spar bench
Upper and lower flanges removed from the jig
One end of the flanges after a lot of "tapering"
Upper spar flange complete with a scarf joint
Wing attach and landing gear blocks "in the raw"
Attach blocks fitted the LHS of spar
7.5m of spar flanges, diaphragms etc in my driveway
A good view of the dihedral
Since the above photos were taken, I have fitted 2.0mm birch ply shear webs to both sides of the spar and some 5.0mm doublers to the landing gear area. Work has begun on the rear spar and drag spars as well as some wing ribs. I have had to re-make some ribs due to my decision to fit reflexing flaps (a 1996 improvement by Stan McLeod) instead of the original split flaps.
Below are some photos of the main spar, sub spars, wing ribs and the beginings of ailerons. The progress so far to August 2001.
Section of the main spar with the shear web attached
The completed main spar
Frame work for rear spars and one drag spar
The drag spars with the shear web attached
Centre spar with shear web being attached - rear view
Centre spar with shear web being attached - front view
Two sets of wing ribs - sick of routing already!
Rear rib #10 being attached to the spar - using the nose rib for reference
Rear ribs #0 - #5 attached to the spar - a couple slightly prematurely
Rib block glued into place - staples are handy as clamps
Take the rib block back off again! The drag spar wont fit with this rib here! AAARRRGH!!!
Aileron ribs in place on the aileron spar - note the strange angle
Aileron ribs at the hinging point
Aileron spar with ribs attached - no trailing edge etc yet
Rebuilt instrument panel bow in progress
Close up of panel bow laminations
The rebuilt panel bow features above as I wasn't satisfied with the original version and I wanted another 10 mm of height for instrument clearance. I suppose that it's better to change such things now rather than be annoyed with a permanent problem.
Progress lately has been slow (Isn't it always?) largely due to the difficulty in obtaining suitable steel for the landing gear (5" X 1/2" 6150 steel) or an alternative at a reasonable price (i.e. spring aluminium or fibreglass). In the meantime, I obtained some 4130 Chrome Moly steel to make most of the required fittings, hinges, joysticks etc. The engine mount is missing at the moment due to the lack of engine (probably a Jabiru 3300 would be a good proposition). Below are a couple of photos of the metal pieces I have managed to create so far. (April 2002)
A selection of metal bits mostly aileron hinge parts and the flat pieces for my dual control joystick setup
The elevator control horn - I intend to connect pushrods instead of cables for elevator control
The long awaited steel finally arrived in July 2004
Some test joints I have made using FGI ES180 epoxy and some other miscellaneous jigs & tools:
Test joint #1 - Douglas Fir
Test joint #2 - Douglas Fir
Test joint #3 - Part of a gluing ability assessment test
My home made ply scarfing sander with tilting table
The beginnings of a Comm antenna the plans of which appeared in a Kitplanes Magazine article a few years ago:
Balsa core - side view
Balsa core - end view
Balsa core with copper tape added
Closer view of the core and copper tape
The core and tape covered with fibreglass and epoxy
The radio end of the antenna ready to fit the base and BNC connection
To learn about the history of the Cavalier 102.5 and its development, please visit my History Page
To see how other Cavalier builders are going, take a look at the pictures on The Builder's Photos Page
To see what can happen to you if you don't get out enough, or if you need a distraction, go Garage Flying
To find out about some other Cavalier builders and owners around the world or where to get plans, please visit the Cavalier Home Page
LATEST NEWS - February 2006
There is now a discussion group for Cavalier & Jungster Builders!
The group has been established for sharing information between builders, builders questions, material sources and qualities for the SA102 to 104 Cavaliers, Super Cavalier, Jungster 1 biplane and Jungster 11 monoplane.
Visit the Google Group now at Cavalier-and-Jungster.
PLEASE NOTE
This page will be updated with pictures and information regarding the construction of my SA102.5 Cavalier regularly/irregularly as time and photos permit. In the meantime, if you have some helpful hints or some Cavalier photos I could use, please don't hesitate to email them to me at
sab@keypoint.com.au
Back to Simon's Home Page
sab@keypoint.com.au