1 Contents Information eon References _ 5 Table layout 7 Sides 9 Side A 10 11 Side B 12 43. Ply. layout on sides 4 Contents 9 “Ss Re RS FR BR LS Fire wall and-front cartythrough. Rear of body and rear carrythrough. Diagonal placements, top and bottom ply. locations Landing gear and tail. wheel Decking, windshield, and the instrument panel. Stabilizer and elevator. Vertical fin and rudder Page #1BS a2 2 eae 8 2 sf 8B ses @ 0 ‘ 2 Contents The seat. floor board and rudder peddles Ribs and the rib jig layout Rear of the wing and the aileron attachment. Nose rib and the front and rear spar view Front and rear spar layout Wing fittings #1 Wing fittings #2 Wing assembly Wing tip bow . Ailerons and the aileron linkage Control quadrant. elevator and rudder linkage Wing attachment and alignment Engines Covering and painting Weight and balance Page #2The Ultra Baby {Wing Span 2508. [Range . j : 12S eq 8 [Takeoff Dist a [Length coco 600K {Landing Dist oo 00, |MaxGross We Ds [Empty We 300 Ibs 35 mph Payload (Full fae)... 280 tbs “Fuel Capacity 5 gal Chim Rate @mmst 600 fpm (Seats oe | Service Ceiling ......... 10,000 - [Engine 35-52 hp Building time 700 hts | Plans $75 00 ‘Construction woodfebricThis page has been ommited, due an information about original plans~ set ownerZx 4 outer body side alignment strips / 4x14 table Draw an outline of the body sides - on the table. Use page #7 as a guide. Side #2 K << top rail must. be perfectly straight. \ A = it would be @ good idea to examine the S plans carefully to be sure you understand them before you start. you can use waxpaper to prevent the wood from sticking to things you don’t want it to. g make some blocks simular to these GZ out of some scrap 2x4" ran/ \ Waxpaper Page #5Page #6top and bottom longrons ara one piece all other members are cut ‘and glued in place. after glue has dried put wax paper at glue jolnts and bulld another side over the first. be sure both sides are-alike and let dry thoroughly. filer block to us" support front 127 of landing gear a Sexe From hare Fig. B So page #11 Note before cutting or gluing see pages — #9 HL 3 #19 #28 See page #9 Page #7Page # 8axa 12 to front of the seat ront seat support 7 rear of the seat support 414 hole @t-—————-f-}-----—--—-—---—-— aa a to the front cockpit member add these plates after each side is complete 16° from the top of the longeron to the top of the seat support \ 3 mm ply > 3 mm outer skin axa v 4x3)" NOTE the-wood is bent at both front and rear cockpit member locations hole for attaching the seat belt Page #9 —_—___Page # 10XS xe" hardwood block scrape glue out of cofners before dry so gussets will fit later #4 x4" thick hardwood block 45 deg. cut off for slevator clearance. Page #11Page # 12Before removing sides from the table, staple some anm plywood strips across each side so they keep their shape when they are taken up. Use page #7 and view the pictures.then place your plywood under each side and mark their location. Be sure to make one left and one right side. Scarf the wood well where the glue is to go (the opposite side of the ply. you marked.) glue and make sure each piece of the ply is tight against the sides, and stapled and clamped in place. Let the sides dry. 0 cg sn 8 | 3 mm = Sma bye r wide ae By. Put @ foot hole here on the fight side if you don’t use the wing walk. 3mm ply 3° wide and cut to fit this piece only some of the ply. caf be cut out for lightening holes see pictures. note ply. grain should run front to back ~ Page # 13Page # 14WAX? Cross bars top and bottom pe Fire wall iz at the tron 1/8ply. for firewall 1'x1°x1/8 Aumn, channel 6061-76 Alumn. glued to front cattytrough for the upper ic wing support cables, Side”assembles o 6 A*x1"xt/8" Alunn. 6061 Longerons qussets all four corners (4) 3/16" holes Ne bolts Page # 15Page # 16cit holes drilled ite Se" x34" rear of the seat back support goes Ck <3 cockpit cross piece : ic Top\and bottom here: see pictures 1.5mm ply. on sides 3 mm pl techy. . cookgi t'xt"t/8" Alum, 6061 T6 HI ct back rear of wing carry throught” = Hard wood block f fests Front of seat support a oF 8 over = bottom longrons 718 FIL floor Botton e4M Qe bottom of plane Stim ‘ply. Used'to sandwich tall wheel 5 radious for block to bottom longrons control stick Page #17Page # 18GUSSETS are where the strength of a joint realy is so make sure LOOKING FROM THE FRONT you scarf the plywood and clean TOWARD THE BACK H both gluing surfaces. good. ' ' i i \ i gussets on the 6 front_side S16 xa/4 al gussets on the back side x3! longrons, On the work table, using a chalk line, snap three ines exactly 12 1/8" apart. this 24 1/4" dim. is the outside of the body. Make-a line at the end of the three lines 90 deg. to them to use for your firewall location, with the top longrons parallel and laying flat on the table. Use blocks of wood fastened to the table at sections B.C.D. on both outside locations, Cut. clamp, and glue sections B.C.D in place. Use a square and strips of plywood stapled to both sides to help hold things together. Let all this dry. When dry see pages # 10 17 19 and pictures to complete joining of the halves. While stil held in place and square on the table put the bottom plywood on. Take the time to scarf, clean, glue, and clamp the surfaces together for a strong body. Anywhere two pieces of wood are butt jointed and glued there probably Is a gusset holding them together, too. Page # 18APage # 18Turn the body over and clamp to the table. using the pictures and page # 19 complete putting the ply wood on the. sub top. cut this_out , splice see page #23 for this dimension. cut this out , | uae 4 s i i / i oe 16 1/4*—+— 16 3/4 4 Body width " chalk line nied i ton center 0) I f m iyeenter line , Page # 19Page # 2Page # Qa