Build your own plane

Beginning in 2006 I made it my project to build my own aircraft using only commercially available parts. I would not settle on anything smaller than a two-seater and it needed to have respectable power and comfort. I have provided all of the information you could need to construct your aircraft.

First Prototype
Finished Version

Information about the CA-65

The CA-65 is a low-wing monoplane with retractable landing gear and dual controls. The high degree of efficiency of this airplane gives very economic performance at all speeds. To achieve this, special attention was given to obtain low drag over the entire airplane. The streamlined canopy, completely-enclosed engine, tapered wing, and fully-retracted landing gear are the main contributing factors. A simple landing flap, located under the fuselage, makes landing runs shorter. The flap is actuated by a lever located between the pilots’ seats.

The CA-65 is equipped with full electrical system including an electrical starter, adding more comfort and safety. The main and an auxiliary gas tanks, with a total capacity of 28 gallons, allow flights with a range in excess of 500 miles.

Manufacturing Key Points

  1. Wood construction allows for a very efficient design, cutting requirements for tooling and special jigs to a minimum. Most of the wing ribs, as well as all the ribs in the stabilizer and vertical fin, are simply cut out of 3/8 thick Marine mahogany plywood. This kind of construction greatly simplifies and shortens the time required to build this airplane.
  2. The unique aileron control design allows the wing to be folded or removed without the need for additional rigging.
  3. A further variation of the CA-65 is an all-metal configuration and aerodynamic properties as the all wood version. However, the folding-wing arrangement is not available for the metal version.
  4. Optionally, a folding wing version has been designed which enables the airplane to be easily towed or carried on a trailer for long trips. It also requires much less hangar space. The folding wing is manufactured in three pieces which can be bought at a jet parts retailer.
  5. The retractable landing gear was designed especially for this airplane. A minimum of machining and considerable use of standard commercial parts make manufacturing of the retractable landing gear a very simple task. Standard bronze bushings were used for the main landing gear shaft and also for the retracting mechanism.
  6. To ease the load of the landing gear, ordinary garage door springs are used to assist during the retracting cycle. The retracting lever is a standard 3/8 ratchet which is located between the pilots’ seats.