You are on page 1of 24

OSVALDO DURANA

OS

VA

UR
OD
LD

AN

FIGHTER ULTRALIGHT

Three view
Plans delivery.com Designed and drawn by Osvaldo Durana

DETAIL A

Long Inner Bushing

AN Bolts

TAIL BOOM

Bolt AN4
Hinge
Short Inner Bushing

Tail fittings
Struts
(dotted lines)

Control Tee
Self locking nut

DETAIL B
Inner Bushing

Pop Rivet

A
Struts assembly details

B
OS

Strut Upper Link

VA

LD

DU

RA

NA

Dia. 25,4 (1)

Contour to fit
elevator tube

25,4
(1)

Tail group Strut


Bolt AN4

(to fit tube)

Dia.6,35
(.25)

Bolt AN4
Clevis Pins
(use with safety lock pins)
Strut Lower Link

FIGHTER ULTRALIGHT

Tail Group assembly


Plans delivery.com Designed and drawn by Osvaldo Durana

RUDDER .

SHORT BUSHING

Dia. 6,35 (.25)

Inner Bushing (short)


203
(8)

406
(16)

12
(.47)
22 (.86)

Tap for AN4


Bolt

Tap for AN4


Bolt

30 (1.18)
60 (2.36)

Dia. To fit
snuggly
into 25,4
(1) tubes

5 21,5
Dia.25,4
(1)

Dia.25,4
(1)

12
(.47)

Material Aluminum

22(.86)

5 =(.197)
21,5 = (.846)

Rad.127
(5)

558 (22)

Dia. To fit snuggly


into 25,4 (1) tubes

36 (1.42)

LONG BUSHING

Radius 127 (5)

15 (.59)

TAIL GROUP
FITTING

FIN
Rad. 11
(0.43)

Dia. 19 (3/4) x
1,65 (.065)

35
(1.38)
Dia. 6,35
(.25)

Bend line

Built with aluminum alloy tubes 6061-T6 - Diameter 1 - wall thickness .065

56
(2.20)

Material
304 Stainless Steel
1,5 (.063) thickness
3 Required.

Rad. 127 (5)

225 (8-7/8)

Dia.19 (3/4) x
1,65 (.065)

92 (3.62)
114,5 (4.5)

1360 (53-1/2)

1255 (49-7/16)

Hardwood bushing

Rad. 9
(.35)

Long Inner
Bushing
127 (5)

B
482
(19)

70
(2.76)
Dia 6,35
(.25)

Rad.12,7
(.50)
Dia 6,35
(.25)

CONTROL TEE
33 (1.30)

2024-T3 Aluminum
5 (.190)Thickness
1 Required

30 (1.81)

127
(5)

Rad. 9 (.35)
450
(17-3/4)

FIGHTER ULTRALIGHT

Tail Group /Rudder


Plans delivery.com Designed and drawn by Osvaldo Durana

ELEVATOR .
127
(5)

130
(5.11)

1185 (46-5/8)

Built with aluminum alloy tubes Quality 6061-T6 - Diameter 25,4 (1)
Wall thickness .065

425 (16-3/4)

600 (23-3/8)

Lower link attachment point


(see plan #2)

B
B

Dia. 19 (3/4) x 1,65 (.065)

Rad. 152 (6)

Dia. 25,4 (1) x 1,65 (.065)

203 (8)

2500 (98.425)

Lower link attachment point


(see plan #2)

101 (4)
R

301 (11-7/8)

R 152 (6)
27
625 (24-5/8)

UPPER LINK .
Stainless Steel
1,5 (.063) Thickness
1 Required

25,4
(1)
Dia. 5
(3/16)

Dia. 5
(3/16)

R 225 (8-7/8)

Dia. 6,35 (.25)


930 (36-5/8)

Dia.5 (3/16)
17 (.67)

50,8 (2)
Dia. 5 (3/16)

Drill to fit Clevis pin Dia. 5 (3/16)

Dia 15 (5/8)

TAIL GROUP STRUTS .

Aluminum tube Dia. 15 (5/8) x 1.65 (.065)

1,5 (.060)

2 Required

Length*
30 (1.18)

LOWER LINK .

Stainless Steel 1,5 (.063)


2 Required

* Once the tail group is built and assembled, align it and


take the exact measurement of the struts

FIGHTER ULTRALIGHT

Tail Group /Elevator


Plans delivery.com Designed and drawn by Osvaldo Durana

WING
A

Wing Spar
Wing Tip

Wing Spar Bracket

Aileron
Wing rib

Boom
Compression Struts
*
See Details A, B, C, D, E and F on Page 6

Wing rib Detail


Turnbuckles
+

Rib/Spar attachment
Compression Strut
Reinforcement Bushings
Link
OS

Bolts

VA

LD

DU

RA

NA

Wing strut fittings

Turnbuckles

Tensor Cable

Rear Spar
Wing Root

Front Spar
Wing Spar

FIGHTER ULTRALIGHT

Wing /Assembly
Plans delivery.com Designed and drawn by Osvaldo Durana

DETAIL A

DETAIL B

DETAIL C

Aileron Ribs Aluminum tube Dia. 9,5


(3/8) 0,90 (.035) Wall Thk
Trailing edge tube
aluminum Dia 15,8 (5/8)
Aileron Spar Aluminum tube Dia.
1,47 (.058) Wall Thk
38(1-1/2) 1,47 (.058) Wall Thk

Aluminum Sheet tip


Aileron Spar
Wood screw

Steel pop rivet

Hardwood insert

Aileron Rib

DETAIL F

Aileron Tip Assembly

Wing Tip

Aleron Root

DETAIL D

Wing Spar
Aileron Spar

Reinforcement Bushing
Plastic bushing

25,4 (1)

DETAIL E

5 Steel pop rivets

Wing Spar

Hinge
Hardwood Bushing

50,8
(2)

Tensor cable

30
(1.18)

Link
Bolt

Hardwood inner reinforcement


101(4) long.
4 Reqd.

Aileron Control Arm

FIGHTER ULTRALIGHT

Wing /Details
Plans delivery.com Designed and drawn by Osvaldo Durana

Wing .

Spars: 2024-T3 Diameter 50,8 (2) -1,65 (.065) wall thickness - Compression Struts 2024-T3 Aluminum tube Dia 25,4 (1) - 1,65 (.065)Wall Thk

Top view

200(7.87)

Wing root

4520 (177.95)
2970 (117)

1320 (52)
550(21.65)

Wing tip bolted


to rear Spar

200 (7.87)

ble
ca
r
o
ns
Te

Hinge

Compression strut

Hinge

Compression strut

Wing Tip

Wing ribs (9 per wing)

Front Spar

Trailing edge
20

1170 (46.06)

Hinge

Aileron

101 (4)

Hinge

Dia 15,8(5/8)

260(10.23)

640 (25.19)

4450 (175.20)

Wing Brackets .

Mat: Stainless Steel - 2,5 (.100) Thick - 4 Required

6061-T6 Aluminum Tube Dia


25,4(1)
R160
(6.30)

2 Required

200(7.87)

150(5.90)
1175(46.26)

Dia 8
(.312)

54 (2.12)

Dia11
(7/16)

Bending line

Wing Tip .

Dia 8
(.312)

R 16
(.63)

54(2.12)
150(5.90)

FIGHTER ULTRALIGHT

Wing /Construction Details


Plans delivery.com Designed and drawn by Osvaldo Durana

AILERON CONTROL ARM


R 18
(.70)

74
(2.91)

R. 17
(.67)

R. 9 (.35)

50
(1.97)

Dia. 6,35 (.25)


70
(2.75)

Bend around Dia 8 (.312)


to get a U shape

80 (3.15)

R. 17
(.67)

STRUT INNER LINK

2024-T3 Alum.
Thickness: 5 (.190)
8 Required
35

(1.38)

Dia. 8 (.312)

50
(1.97)

Mat: Stainless Steel


Thickness: 2 (.080)
4 Required

108

Dia. 6,35
(.25)

R.16
(.63)

Dia. 6,36 (.25)

Dia. 8 (.312)

R. 44 (1.73)

WING STRUT FITTING

72
(2,83)

R.16 (.63)
87
(3.42)

R. 17
(.67)

WING STRUT TIP

4130 Steel
Thickness: 2 (.80)
8 Required

50
(1.97) Dia 8

Material 2024-T3 aluminum Thickness 5 (.190) 2 Required

(.312)

Dia 5 (.187)

HINGES

Mat: Stainless Steel 1,5 (.063) Thick


14 Required

20
(.80)

2 (.080)

Chamfer Detail

8 (.31)

SPACER

13
(.51)

23
(.90)

25

R 8 (.31)

22 (.86)

Mat: Steel
2 (.080) Thick.8 Required

14
(.55)

Dia. 8 (.312)

R. 17
(.67)

R.15 (.60)

LINK

9
(.35)
30 (1.18)

180 (7.08)

38 (1.50)

20
(.80)

73
(2.87)

Dia 3(.12)

Bending lines

15 (.60)

Dia.6,35
(.25)

5 (.20)
112 (4.41)

R.11 (.43)

30 (1.18)

84 (3.30)

Dia.6,35
(.25) Dia. 8
(.312)

30 (1.18)

Dia.6,35
(.25)

Bend 90
upward by
dotted lines

Dia. 3
(.12)

R
53 (2.08)

5 (3/16)

104 (4.09)

Material :Stainless Steel


Thickness 1,5 (.063)

8 Required

232 (9.13)

AILERON TIP

Mat: Aluminum sheet 2024-T3 - 0,7 (.025) Thick - 2 Required

FIGHTER ULTRALIGHT

Wing /Construction Details


Plans delivery.com Designed and drawn by Osvaldo Durana

161
(6.338)

165
(6.496)

168
(6.614)

189
(7.441)

Mat: 2024-T3 Aluminum Sheet


0,7(.025) Thick - 36 required

Drill for pop rivets

101
(4)

1170
(46.063)

25,4
(1)

70
(2.76)

171
(6.732)

Wing ribs are made from aluminum alloy tubes Dia. 9.52 (3/8) .035 wall thickness
riveted from leading edge spar to trailing edge spar.

Wing Rib Attachment


30
(1.18)

171
(6.732)

172
(6.772)

170
(6.693)

167
(6.575)

163
(6.417)

158
(6.220)

150
(5.905)

142
(5.590)

130
(5.118)

115
(4.527)

95
(3.740)
72
(2.835)

25,4
(1)

Detail rear spar

FIGHTER ULTRALIGHT

Wing /Airfoil-Wing rib


Plans delivery.com Designed and drawn by Osvaldo Durana

DETAIL A
Fuselage Front end
Exploded view

Front mast

DETAIL B
Boom ring
AN5 Bolts

Fuselage nose plate


(upper)

Central Brackets

Fork

Central boom support


Bushing
Rear boom support
1
2
Fuselage nose plate
(lower)

Side member
Rear member

Front mast
Reinforcement
tube

B
A
Side member

2
4

Fork

Nose wheel

1) Boom support bracket


2) Rear link plate
3) Wing strut link plate
4) Landing gear mounting bracket

Side member

FIGHTER ULTRALIGHT

Fuselage/Cockpit - Assembly Details


Plans delivery.com Designed and drawn by Osvaldo Durana

10

40(1.57)

530(20.86)
153(6.02)

3900 (153.54)
650(25.60)

1170(46.06)

Boom

1550(61.02)

Mat: 6063-T3 Aluminum Tube


Dia 101 (4) 2 (.078) Wall Thk

463(18.23)

90(3.54)

240(9.45)

437(17.20)

Central Plate

135(5.32)

Mat: 2024-T3 Aluminum 5(.190) thick - 1 Required


R 180 (7.09)

Rear Boom
Support

168(6.61)

Mat: 6061-T6 Aluminum


tubes Dia 28 (1-1/8)
1,5 (.058) wall Thickness
2 Required (rigth/left)

R 150(5.90)

Central plate
Riveted here

5
(.196)

Dia 101(4)
8
(.312)

150(5.90)
1360 (53.54)

Mat: 6061-T6 Aluminum


tubes Dia 28 (1-1/8)
1,5 (.058) wall Thickness
2 Required (rigth/left)

950 (37-7/16)

Central Boom Support

280(11.02)

Fuselage Rear Member

25,4(1)

Mat: same as side member-1 Reqd.


74(2.91)

Fuselage
Side Member
Mat: 2024-T3 Aluminum
tubes Dia 50,8 (2) 1,65
(.065) Wall Thickness
2 Required (left/right)

101 (4)
700 (27-9/16)

101
(4)

101
(4)

101
(4)

75(2.95)

101
(4)

101
(4)

101
(4)

101
(4)

380(15)

10(.39)

25,4(1)

45(1.8)

530(20.87)

110(4.33)

155(6.10)

210(8.27)

270(10.63)

340(13.38)

1140(44.88)

101
(4)

300(11.81)

1460(57.49)

35(1.38)

Dia 8
(.312)

74(2.91)
730 (28-3/4)

R 336 (13-1/4)

Dia 28
(1-1/8)

R 336
(13-1/4)

50.8(2)

700 (27-9/16)

25,4(1)

FIGHTER ULTRALIGHT

Boom / Fuselage components


Plans delivery.com Designed and drawn by Osvaldo Durana

11

90(3.54)
60(2.36)

74(2.91)

105(4.13)

Dia 8
(.312)

Boom support bracket

R 15
(.60)

Mat: Stainless Steel -2 (0.80) Thick -4 Required

Mat: 2024-T3 Aluminum


5 (.190) Thick
4 Required

Landing Gear Bracket

Dia 8
(.312)

!4(.55)

Mat: Stainless Steel


2 (.080) Thick - 2 Required

36(1.42)

Dia 8
(.312)

Dia 8 35(1.38)
(.312)
R13
(.51)

60(2.36)
90(3.54)

26(1.02)

Bend 7 upward

Dia12,7(1/2)

2(.080)

92 (3.62)

88 (3.46)

Bending line

66 (2.60)

40(1.57)

R 15
(.60)
Dia 8
(.312)

Mat: Stainless Steel 2 (.080) Thick -2 required

Wing Strut Link

210 (8.27)

35(1.38)

40(1.57)

R11
(.43)

71 (2.80)

Mat: 2024-T3 Aluminum 5 (.190) Thick 2 Required


(Upper/Lower see instructions)

230 (9.05)

2(.080)

60(2.36)

90 (3.54)

Dia 8
(.312)

26
(1.02)

Fuselage Nose Plate

Rear Link Plate

90 (3.54)

2(.080)

20(.79)
Pop rivet to boom

80 (3.15)

46
(1.81)

Section

Bend around 4 tube and


comform like this

57
(2-1/4)

Boom Ring
Mat: 2024-T3 Aluminum 3 (.125) Thick
1 Required

Dia 8
(.312)

FIGHTER ULTRALIGHT

340 (13.38)
370 (14.57)

Fuselage brackets
Plans delivery.com Designed and drawn by Osvaldo Durana

12

FORK

FRONT AXLE

62 (2.44)

Link from
pedal
attachment
point

Mat: Steel tube


2 (.83) Thick

320
(12-5/8)

FRONT FITTING

Mat: Steel

Steel Tube
Dia 22 (7/8)
1,2 (.049) Thick

660 (26)

2,5 (.100) Thick

353 (13-7/8)

LANDING GEAR
Front View

425
(16-3/4)

Steel Tube
Dia 22 (7/8)1,2 (.049) Thick
62 (2.44)

Dia 44
(1-3/4)

165 (6-1/2)

Steel Tube
Dia 22 (7/8)
1,2 (.049) Thick

90
(3.54)

Dia 12,7 (1/2)


2 (.083) Thick.

Welded Reinforcement

Attach Clevis Pin

Cotter pin
Weld

Steel Tube
Dia. 12,7 (1/2)

REAR LANDING GEAR LEG

DETAIL
Axle housing
To slide fit axle

6 (.23)

Drill for cotter pin


(each end)

Landing Gear Pivot Bracket

30 (1.18)

Mat: Steel 2 (.080) Thick

4 required

R 15 (.60)

FORK HEAD

R 12 (.47)

Mat: Steel 2,5 (.100) Thick


2 required
Dia 9,5 (3/8)
Dia. 12,7 (1/2)
Fit to slide steel tubes

134 (5.27)

Brake Attachment Fitting


Dia 22 (7/8)

Dia 8 (.187)

10 x 10 (.39 x .39)

Welded steel washer


46 (1.81)

R. 17 (.67)

14 (.55)

3 (3/16) Thick

52 (2.05)

Tap (see rear axle)

R 17 (.67)

30
(1.18)

12,7
(1/2)
110 (4.33)

50,8
(2)

Mat: Steel 2 (.080) Thick

2 required

FIGHTER ULTRALIGHT

Landing Gear
Plans delivery.com Designed and drawn by Osvaldo Durana

13

Rear axle

Landing gear leg

Mat: Steel - 2 Required


Dia 22 Dia 17 Dia 16
Dia 15
(.87) (.67) (0.63)
(.60)

Brake positioning lug


Thread

25,4(1)
42(1.65)
52(2.04)
86(3.38)
100(3.94)
115(4.53)

Brake plate
Rear axle
Spring
Brake arms

2(.08)

Thread

Wheel

Brake drum
Inner wheel half

Bearing
Bearing housing

Bearing housing

Inner wheel half

Bearing
Control cable

Actuator arm

SV

AL

AN

Self locking nuts

Slot for positioning lug

Brake plate rear view

FIGHTER ULTRALIGHT

Rear Wheel Assembly / Axle


Plans delivery.com Designed and drawn by Osvaldo Durana

14

Central Bracket
Mat: Stainless steel - 2,5 (.100) Thick 2 Required

Dia 11
(7/16)

Bending line

Dia 8
(.312)

Dia 8
(.312)
30(1.18)

R 16
(.63)

Central brackets
OS

D
AL

DU

RA

NA

Front Mast
Aluminum Alloy tube Dia 32 (1-1/4)
1,47 (.058) Wall Thk
Lenght: 1000 (39.37)

30 (1.18)
62 (2.44)

Side Stick
Aluminum
tube Dia 25,4 (1)
300 (11.8) length
Torque tube
Aluminum Dia 25,4 (1)
500 (19.68) length
attached to longerons
by Nylon bushing
(allowing rotation)

Control Arm

FIGHTER ULTRALIGHT

Fuselage /Tail Boom Assembled


Plans delivery.com Designed and drawn by Osvaldo Durana

15

AILERONS
PEDALS

RUDDER

MIXER

CONTROL SIDE STICK

ELEVATOR

CONTROL CABLES
TELEFLEX TYPE
TAIL GROUP

FIGHTER ULTRALIGHT

Control System
Plans delivery.com Designed and drawn by Osvaldo Durana

16

2(.090)

** Insert in torque
tube before drill.
**5(.187)

R15(.60)

R13(.51)

12,7(1/2)

10(.40)

47(1.85)
40(1.60)
104(4.09)
12(.48)
R
R3(.12)

30
(1.18)

38(1.50)

155 (6.10)

*Dia22(.87)

26(1.02)

Pedal Tang
15(.60)

R9(.35)

Weld
Dia. 5
(.187)

5(.187)

Aileron Control Link

Mat steel tube Dia 11(7/16) - 2 Required

6,35
(1/4)

20(.79)

33(1.30)

170(6.70)
Mat: S.Steel 2(.090)
2 Required

Rod End Bearings


Male thread

Tap tubes 1/4-28 thread or


weld nut at both ends

32(1-1/4)

5(.187)
25,4(1)

6(.24)

5
(.187)

20(.79)

Bending lines
11(.43)

12(.47)

15(.60)

85(3.35)

8(.312)

60(2.36)

15(.60)

Push-Pull Barr end Mat: Aluminum- 1 Required


36(1.42)

Dia 12,7(1/2)

20(.79)

32(1.26)

60(2.36)

R10
(.40)

130(5.19)

Mat: Grilon 4 Reqd.

15(.60)

12(.47)

Pedal Bushing

2(.090)

3,5(.137)

Mat:Steel 1 Rqrd.
6,35(1/4)

10(.39)

36(1.42)

60(2.36)

25,4
(1)

12,7(1/2)

12,7
(1/2)

Aileron mixer

R13(.51)

36(1.42)
45(1.77)

50,8(2)
Dia 8
(.312)

8
(.312)

285(11.22)

R 3 (.12)

weld

Mat: Aluminum sheet 3(.125) thick. -2 Required


130(5-1\8)
101(4)

5(.187)

Pedal

Dia12,7(.5)

53(2.08)

5(.187)

**5(.187)

Mat: Steel - 1 Reqd.

50(1.97)
76(3)

Control Arm

12,7(1/2)

*Dia 22(.87)

35(1.38)

47(1.85)
135(5.31)
55(2.16)

* Diameter to fit snuggly in 1 dia. alum tube

*Dia 22(.87)

12,7(1/2)

Control Stick end Mat: Aluminum- 1 Required

101 (4)
140 (5.51)
200 (7.87)

FIGHTER ULTRALIGHT

Control components
Plans delivery.com Designed and drawn by Osvaldo Durana

17

PEDALS

WING STRUTS
Steel tube to connect teleflex

REAR SPAR
Bushings

FRONT SPAR

Steel cable connect to fork

Wing strut
fitting
Strut inner link

Aluminum tubes

Spacers
Wing strut tip

Wing Strut

Weld
Wing strut are made from
streamlined steel tube.

THROTTLE ASSY
FIGHTER ULTRALIGHT

Wing Struts / Pedals Assembly


Plans delivery.com Designed and drawn by Osvaldo Durana

18

ENGINE

Rubber mounts

Upper Bracket

Lower Bracket

Side Bracket

OS

D
AL

DU

RA

Boom

NA

External Adapter

Inner Adapter
FIGHTER ULTRALIGHT

Engine Mount Assembly


Plans delivery.com Designed and drawn by Osvaldo Durana

19

Side Bracket

Engine Mount
Front View

1)
135

Inner Adapter

Mat: Stainless Steel


3 (1/8) Thick
2 Required

25,4
(1)

Mat: Aluminum 2 required

164 (6.46)

135

135

Boom

Bending Line

3)

60
(2.36)

273 (10-3/4)

1)

65
(2.56)

Bending Line

R 10
(.39)

65 (2.60)

50,8 (2)
50,8 (2)

NOTE
1) Diameter according Rubber
mounts

2) Diameter according engine bolts


3) Length according engine

25,4
(1)
60
(2.36)

R. 50,8 (2)

65
(2.56)
15
(.60)

310 (12.20)

25,4
(1)

25.4 (1)

R 10 (.39)

25,4
(1)

Dia 8
(5/16)

External Adapter
Mat: Aluminum 2 Required

Bending Line

25,4
(1)

2)

50,8
(2)

50.8 (2)

Aluminum tube Dia. 101 (4)

Bending Line

1)

60 (2.36)

15
(.60)

35(1.38)

R 10 (.39)

Upper Bracket

Dia 8
(5/16)

Bending line
Dia 8
(5/16)

Mat: Stainless Steel


3 (1/8) Thick
2 Required

According inner
diameter of
Boom

50,8 (2)

65
(2.56)

FIGHTER ULTRALIGHT

Engine Mount Details


Plans delivery.com Designed and drawn by Osvaldo Durana

20

220
(8.66)

220
(8.66)

230
(9.05)

220
(8.66)

240
(9.45)

220
(8.66)

220
(8.66)

230
(9.05)

220
(8.66)

230(9.05)

340(13.38)

450(17.72)
710
(27.95)

250
(984)
670
(26.38)

430
(16.93)
550
(21.65)

315
(12.40)
450
(17.72)

290
(11.42)

200
(7.87)

Polycarbonate windshield

240
(9.45)

FIGHTER ULTRALIGHT

Cockpit Enclosure Three view


Plans delivery.com Designed and drawn by Osvaldo Durana

21

Fighter Ultralight
Building guidelines
Welcome! You are about to get involve in one of
the most rewarding projects that you can make
with your own hands:
An ultralight aircraft that will bring you hours of
excitement and fun!
Before starting, take a moment to study the plans,
so you can understand the whole project and how
each part are made and assembled.
Building process
It is recommendable to start with the tail group;
this will give you the experience needed to continue with more demanding or complex parts.
Your workshop and tools
This ultralight can be build in an average home
garage, however more space will be required to
assemble the complete aircraft.
Put special attention to illumination of your work
area, working in a poorly illuminated area will
get you tired sooner and also prone to commit
mistakes (some of them can be costly and some
dangerous)
Keep your shop clean and organized, which will
save you time and effort.
Equipment needed:
A strong worktable is a definitive must.
Measuring tools:
Venier caliper, metallic ruler, measuring tape,
square, center punch, felt point marker pen.
Hand tools:
Hammer, hacksaw with several spare blades (with
different number of teeth per inch, to cut aluminum and steel) pop riveter, files (flat and round,
nd
2 and smooth cut) pliers, aviation snips, combination wrenches, deburring tool, reamers.
Equip your worktable with a medium size vise to
hold the parts been made.
Drill and drill bits, a bench drill press can also be
a great addition to your shop.

Dont forget the safety equipment like eye protectors, gloves, and respirators, always protect your
eyes when drilling or working with power tools.
Well, you got the space, the tools, get some raw
material and start...
Building the Tail group
This is the best starting point, especially to those
of you who need to gain practice in mechanical
constructions.
In the page #2 you can see the tail group assembly and how it is fasten to the boom tube.
In page # 3 you have all specifications needed for
building each element.
Begin with the fin, its the simplest part of the tail
group.
Bending the tubes
If you dont have a tube bender, you can make
your own bending jig
Using a hardwood pulley as depicted in the following drawing.
Support Block

Hardwood pulley
Diameter to fit tube

Harwood pulley

Fasten the pulley and the support block to your


worktable.
Before cutting the tubes to be bend, be sure to
allow material in excess.
Insert a plug into one of the tube ends, pour dry
sand inside the tube, tap gently to compact the
sand inside and place another plug on the other
end, the sand helps to avoid deformation in the
tube when it is bend.
Once the tube is placed in the bending jig, secure
it against the pulley with the support block and
start bending it very slowly, dont try to bend it in
one stroke, you will get wrinkles in the whole bend.
The bending is made little by little moving the tube
forward in small increments till the curve is complete.
Draw the desire curve as a guide in the floor or in
a board and use it to check the progress of the
curve, placing the tube frequently against the drawing. Try not to over-bend the tubes, it will be almost impossible to un-bend.
The most difficult part of this operation is to obtain symmetric o equal curves as the ones required
in the elevator, but dont dismay, with some practice you will be able to create good curves.
After cutting the tubes to the required length use
a small round file or a deburring tool to clean the
inside part of the tube.
The brackets are made from stainless steel sheet,
this material is very tough and you will need well
sharpened drill bits to make the holes, make them
smaller than the diameter required, then use a
reamer in order to enlarge the holes at the right
size (the bolts should fit snuggly)
Draw the contour of each bracket in the steel sheet,
mark the holes with a punch marker, cut along the
lines, clean the cuts with a file and bend as needed,
only then make the required holes.

two o three fillets of the thread should be visible.


If you want to assemble provisory the parts dont
use self-locking nuts, but remember to replace
them when the assembly is definitive.
Use only stainless steel pop rivets; the aluminum rivets will not have the strength needed.
The elevator is linked to the rudder with two
struts, which give strength to the tail and help
to maintain the rudder and the elevator at 90
degrees from each other. You will have to verify
the length of each strut (they should be identical) measuring it once the tail group is finished
and assembled.
The wing
As you study the pages # 5; 6 and 7 you will
realize that the wing is not as complex as it may
seem.
I recommend you to start with the compression
struts, these parts are made from 1 diameter
aluminum alloy tubes, cut them at the indicated
length and then make the stainless steel links
(page 8)
After cutting the spars and prior to start assembling the wing it is advisable to get a large board
where you can place and assembly the complete
wing, since the dimension of each wing is more
large than the average worktables, you can enlarge the working surface of your table or bench,
by placing a particle board over it.
Its a good idea to nail wood blocks to the table
in order to secure the wing spars and other wing
elements being added to the assembly.

Page 5 shows the wing strut fittings bolted into


the spar with two
reinforcement bushing,
which
FIGHTER
ULTRALIGHT
In every assembly check the lengths of the bolts, are made from aluminum tubes.
bushing)
once tighten with a nut (self lockingPlans
nuts)delivery.com
only (Read Reinforcement
Designed and drawn
by Osvaldo Durana

Once the spars and compression struts are bolted


together, you can connect them with the tensor
cables which will give the wing an extraordinary
rigidity
The wing tip tube is riveted to the main spar as
indicated in page 6 (detail F) and bolted to the
rear spar.
Tensor cables
The following drawings show you step by step
how to make them.
The cable used is 1/8 x 1 x 19 steel cable that
can be galvanized or stainless.
(Diameter 1/8 x one strand of 19 wires)
Be sure to measure correctly each cable before
cutting them.

Now with the Nicopress Tool, you can compress


the nicopress sleeve (usually making three grooves
along sleeves length), after that you can take away
the cable clamp and the hose.

At the end of the cable, slide a short piece of rubber hose.


Now slide the nicopress sleeve, make a loop with
the cable and pass the end of the cable again
through the nicopress and the hose.

In the eye formed by the cable, put a thimble and


adjust all the assembly, you can use a cable clamp
to keep them in place.
Thimble

To cut the cable, wrap it with electrical tape and


cut it with chisel and hammer (never cut them
with a welding torch, doing this could modify
their mechanical properties)

This is a Nicopress sleeve that will be use to


assemble the cables.

Cable clamp

Nicopress Tool

Now you can start making the wing ribs, according to the drawing in page 9, to make all ribs equal,
cut a pattern from a inch wood slab and use it
to bend the ribs.
Cut the end of every rib as shown in page 9 to fit
over the main spar.
9 ribs are required for each half wing, and are
riveted to the spars with the attaching fitting (made
from aluminum sheet)
Use a square to align each rib at 90 degrees from
the spars and perpendicular to the span.
Ailerons
Measure and cut to the required length the aileron spar from an aluminum tube diameter 38 (11/2) mark the position of every aileron rib and
drill a small hole through the spar, enlarge the
hole in the inboard face of the spar to accept the
aluminum rib (3/8 diameter tube) the trailing edge
tube is fastened to the ribs with pop rivets.
Once finished, place the aileron next to the wing
in the right position, mark the position of each
hinge, drill and bolt them in place.

num tubes that will support the boom (page 11)


Rear boom support use an aluminum ring (page
12) to attach the boom (dont forget to rivet it
to the boom)
The central boom support tubes (page 11) are
attached to the boom using steel brackets (page
15 Central brackets)
Be careful when making the holes in the boom,
have the tail group in place before attaching the
chassis, this will help to keep the assembly
aligned.
Finally measure and cut the front mast, you can
use a streamlined aluminum tube, and two stainless steel brackets to connect the mast with the
boom tube and the chassis.
Reinforcement bushings
When tubes are to be bolted, to avoid been flattened when the bolt union is tighten, you can
insert a short piece of hardwood or Nylon turned
to fit the inside diameter of the tube.
In some instances the reinforcement can be
achieved using small aluminum tube as bushing.
e.g. for a 5/16 bolt (AN5) use as a bushing a 3/
8 x .028 wall thickness tube
for a 7/16 bolt (AN7) you can use a x .028
wall thickness tube.

Wing Spar (page 5)


Cockpit chassis
Now you can start with the cockpit chassis, cutting and bending the side members, using the
bending method previously explained (you will
need to make another hardwood pulley to accept
the 2 diameter tube)
Cut the straight rear member and make all brackets and plates as explained in page 10 ;11 and 12.
Fuselage nose plate (two are needed: upper and
lower) make the upper first, fasten it to the side
members as depicted in page 10 and using a cardboard as a template trace the lower plate which
will be a little longer in order to accept the fork. (it
1) make the required holes through the spar
could be convenient to have the fork already made) FIGHTER ULTRALIGHT (use a drill bit = bolt size)
Once the chassis is made and all the parts bolted
Plansalumidelivery.com Designed and drawn by Osvaldo Durana
together you can cut and bend the 1-1/8

Bushing
Diameter holes

Bolt diameter holes

the brakes of this craft were taken from a small


motorcycle, you should search for some available
within your zone.
Attaching the wing
Once finished the main groups, and before to cover
the wings, attach them to the boom tube, make a
couple of wing supports out of wood to place the
wings in the right position, verify the dihedral angle
(2,5 degrees) and then take the measure of each
wing strut.

2) enlarge the holes (only on this face of the


spar) to insert the reinforcement bushings, complete the assembly.
Engine mount
The drawing in page 19 and 20 are self explanatory, according to the engine selected you will
have to vary the position of some holes (our prototype used a Rotax engine)
The design of this mount allows it to slide over
the boom tube, dont bolt to it now, when the
airplane is finished you will have to calculate the
weight and balance in order to place the center
of gravity in the right position (between 25% and
30 % of the wing chord) allowing the engine to
be able to slide forward or backward will help to
achieve the right C.G. position.
Landing gear
Page 13 shows all the components of this sturdy
landing gear, almost all parts are made from steel
tubing which are welded using oxyacetylene or
TIG /MIG process, if you dont have the equipment or the knowledge to do the welding find a
welding shop in your area and get your gear
welded.
The EAA have several good books about welding
that can guide you through this process.
Page 14 shows the wheel and brake assembly,

This is just a general guideline to help you to tackle this


project, more information about specifically subjects like
welding, covering or working with composites/fiberglass
can be find at your local library .
Abundant material and help can be found at the Experimental Aircraft Association (www.eaa.org)

Updated Mar-20-2001

Control system
This aircraft employ a flexible push-pull control
system often called Teleflex which simplified the
task and its very reliable.
Covering
This aircraft is covered with Dacron fabric (wings
and tail group, even there are good books that
shows step by step how to cover your airplane we
are preparing an e-booklet that will show how to
do it, if you are interested, please send us a mail.
Fuel Tank
There are many models ready made, attach it to
the central support tubes behind the seat.
A word of caution
Warning! the set of plans and the instructions provided
here are for educational and recreational purposes only,
nor the designer neither Plans Delivery.com can be responsible for injures, property damages or even the
death to someone following the indications given here.
Flying could be a dangerous activity if is not done with
the expertise and knowledge required, we advise you
to take flying lessons prior to attempt to fly in any aerial
vehicle, been this experimental, ultralight or a home
built creation.
Working with power tools, paints, solvents and related
chemicals also can be dangerous to people and property if not done properly.
We advise you to use eye, body protection and follow
manufacturers recommendations.

FIGHTER ULTRALIGHT
Plans delivery.com

Designed and drawn by Osvaldo Durana