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PLANO DE AVIÓN EXPERIMENTAL

24 pag.

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 OSVALDO DURAN
A

A
N
A
R
U
D
O
LD
A
V
S
O

FIGHTER ULTRALIGHT -

Three view

Plans delivery.com Designed and drawn by Osvaldo Durana 1

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 DETAIL A
AN Bolts
Long Inner Bushing TAIL BOOM
Bolt AN4

Hinge

Short Inner Bushing

Tail fittings

Struts
Control Tee
(dotted lines)

Self locking nut

DETAIL B

Inner Bushing
Pop Rivet

Struts assembly details

B
O
S

Dia. 25,4 (1”)

V
A

Strut Upper Link Contour to fit

L
D
O
D
U
R

(to fit tube)

A
N

elevator tube
A

25,4

(1”)
Tail group Strut

Bolt AN4
Dia.6,35

(.25”)

Bolt AN4

Clevis Pins

(use with safety lock pins)

FIGHTER ULTRALIGHT -

Tail Group assembly

Strut Lower Link
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 SHORT BUSHING
RUDDER . Dia. 6,35 (.25”)

Built with aluminum alloy tubes 6061-T6 - Diameter 1” - wall thickness .065” Tap for AN4
Tap for AN4
Bolt Dia. To fit snuggly
Bolt 15 (.59”)
Inner Bushing (short)
into 25,4 (1”) tubes
Dia. To fit
406 203
snuggly 12
(8”) Material Aluminum
12
(16”)
(.47”)
into 25,4 (.47”)

30 (1.18”)
22 (.86”)
(1”) tubes 22(.86”)

B 60 (2.36”)
B 36 (1.42”)

LONG BUSHING
Radius 127 (5”) Rad.127 5 =(.197”)

(5”) 21,5 = (.846”) TAIL GROUP

558 (22”)
5
21,5
5 FITTING

Material
FIN
Dia.25,4 Dia.25,4 304 Stainless Steel
Rad. 11
(1”) (1”)

Bend line
35 56 1,5 (.063”) thickness
(0.43”)
(1.38”) (2.20”) 3 Required.
Dia. 6,35

Dia. 19 (3/4”) x (.25”)

1,65 (.065”)

Hardwood bushing

1255 (49-7/16”)
Dia.19 (3/4”) x 92 (3.62”)

1,65 (.065”)
114,5 (4.5”)

70

1360 (53-1/2”)
(2.76”)

Rad. 9
CONTROL TEE
(.35”) 2024-T3 Aluminum
Rad. 127 (5”)
Dia 6,35 5 (.190”)Thickness

(.25”) 1 Required
Rad.12,7 33 (1.30”)

Long Inner (.50”)

Bushing
225 (8-7/8”)
Dia 6,35

127 (5”) (.25”) 30 (1.81”)

B B

127

(5”)
482 Rad. 9 (.35”)

(19”)
450

(17-3/4”)

FIGHTER ULTRALIGHT -

Tail Group /Rudder

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 ELEVATOR .

Built with aluminum alloy tubes Quality 6061-T6 - Diameter 25,4 (1”)
130 127
1185 (46-5/8”) Wall thickness .065”
(5.11”) (5”)

600 (23-3/8”)

425 (16-3/4”)
Lower link attachment point
Dia. 19 (3/4”) x 1,65 (.065”)
(see plan #2) Rad. 152 (6”)
203 (8”)
Dia. 25,4 (1”) x 1,65 (.065”)

B B B
B
2500 (98.425”)

B B
B B

101 (4”) Lower link attachment point

R (see plan #2)

301 (11-7/8”)

R 152 (6”)

27º

625 (24-5/8”)

UPPER LINK .
R 225 (8-7/8”)
Stainless Steel

1,5 (.063”) Thickness

1 Required

Dia. 6,35 (.25”)

25,4 930 (36-5/8”)

Dia.5 (3/16”)
(1”)

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

Dia. 5 17 (.67”) Dia 15 (5/8”)
50,8 (2”)
(3/16”)
TAIL GROUP STRUTS .
Dia. 5 (3/16”)
Aluminum tube Dia. 15 (5/8”) x 1.65 (.065”)
1,5 (.060”)

2 Required

Dia. 5
Length*
(3/16”)
30 (1.18”)

FIGHTER ULTRALIGHT -

* Once the tail group is built and assembled, align it and Tail Group /Elevator
Stainless Steel 1,5 (.063”)

LOWER LINK . 2 Required

take the exact measurement of the struts
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 WING

Wing Spar

Wing Spar Bracket

Wing Tip 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
Turnbuckles

Rear Spar

Reinforcement Bushings

Tensor Cable
Link
Wing Root
O
S
V

Front Spar
A
L
D
O
D
U
R
A

FIGHTER ULTRALIGHT
N
A

Wing Spar
-
Bolts
Wing /Assembly
Wing strut fittings
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 DETAIL B DETAIL C
Aileron Ribs Aluminum tube Dia. 9,5
DETAIL A
(3/8”) 0,90 (.035”) Wall Thk
Trailing edge tube

Aileron Spar Aluminum tube Dia. aluminum Dia 15,8 (5/8”)

38(1-1/2”) 1,47 (.058”) Wall Thk 1,47 (.058) Wall Thk

Aluminum Sheet tip

Aileron Spar

Wood screw

Steel pop rivet

Aileron Rib Hardwood insert
Aleron Root

DETAIL F
Aileron Tip Assembly Wing Tip
DETAIL D

Wing Spar

Reinforcement Bushing

Aileron Spar

Plastic bushing

25,4 (1”)

DETAIL E
5 Steel pop rivets

Wing Spar Hinge

Hardwood Bushing

50,8

(2”)

Tensor cable
30
Aileron Control Arm
(1.18”)
Hardwood inner reinforcement

101(4”) long.

4 Reqd.
Link

Bolt

FIGHTER ULTRALIGHT -

Wing /Details

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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”)
4520 (177.95”) Wing root

2970 (117”)

1320 (52”)

Front Spar 550(21.65”) 101 (4”)

Compression strut
le

Compression strut
Wing Tip b

Wing ribs (9 per wing)

a
c
r
o
s
n
e
T

1170 (46.06”)

Hinge
Wing tip bolted

to rear Spar

200 (7.87”) Hinge Hinge

Hinge 260(10.23”)
Aileron

Trailing edge
Dia 15,8(5/8”) 640 (25.19”)
20º

4450 (175.20”)

Wing Brackets .
Mat: Stainless Steel - 2,5 (.100”) Thick - 4 Required
6061-T6 Aluminum Tube Dia

25,4(1”)
R 16 Dia 8

(.63”) (.312”)

Wing Tip . R160

Dia 8

Bending line
200(7.87”) 54 (2.12”)
(6.30”)
2 Required (.312”)

Dia11
150(5.90”)
(7/16”)

54(2.12”)

150(5.90”)
1175(46.26”)

FIGHTER ULTRALIGHT -

Wing /Construction Details

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 AILERON CONTROL ARM
Bend around Dia 8 (.312”) WING STRUT FITTING
80 (3.15”)
to get a “U” shape 72
74
R 18 R.16
(2,83”)
(2.91”) R. 17
(.70”) (.63”)
(.67”) R. 17
R. 9 (.35”) Dia. 6,36 (.25”) 2024-T3 Alum.
(.67”)
50
Thickness: 5 (.190”)
(1.97”)
Dia. 6,35 (.25”) 8 Required
35
Dia. 8 (.312”)
(1.38”)
Dia. 8 (.312”)
70
R. 44 (1.73”)
STRUT INNER LINK
(2.75”) 50
Mat: Stainless Steel
(1.97”)
Dia. 6,35 108º Thickness: 2 (.080”)
(.25”) R.16 (.63”)
4 Required

87
R. 17
(3.42”)
WING STRUT TIP
(.67”)
4130 Steel
50
Thickness: 2 (.80”)
Material 2024-T3 aluminum Thickness 5 (.190”) 2 Required (1.97”)
Dia 8
8 Required
(.312”)
73
2 (.080”)
Dia 5 (.187”) (2.87”)
R 8 (.31”)
8 (.31”)
HINGES Chamfer Detail
Dia. 8 (.312”)

20
22 (.86”)
R. 17
Mat: Stainless Steel 1,5 (.063”) Thick
(.80”)
13
SPACER
(.51”)
(.67”)
14 Required
Mat: Steel
14
23
2 (.080”) Thick.8 Required
(.90”) (.55”)

25º
R.15 (.60”)

LINK
9
Dia.6,35
(.35”)
(.25”) 30 (1.18”)
30 (1.18”)
84 (3.30”)
180 (7.08”) 5 (.20”)
R.11 (.43”) Dia.6,35
112 (4.41”) 30 (1.18”) (.25”)
Dia 3(.12”) Dia. 8
Bend 90º
20 (.312”)

(.80”) upward by
Bending lines 15 (.60”)
38 (1.50”)
Dia. 3 dotted lines
Dia.6,35
(.12”)
(.25”)

Material :Stainless Steel

53 (2.08”)
5 (3/16”) 104 (4.09”) Thickness 1,5 (.063”)

8 Required

232 (9.13”) FIGHTER ULTRALIGHT -

Wing /Construction Details

AILERON TIP Mat: Aluminum sheet 2024-T3 - 0,7 (.025”) Thick - 2 Required Plans delivery.com Designed and drawn by Osvaldo Durana
8
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 (4.527”)

(6.575”)
(6.220”)

(6.693”)
(6.417”)

(6.772”)

(7.441”)
(5.905”)

(6.732”)

(6.614”)

(6.496”)
(3.740”)

(6.338”)
(6.732”)
(5.590”)
(5.118”)

167
158

170
163

172

189
150

171

168

165

161
171
115

142
130
95
(2.835”)
72

25,4

(1”)

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

Mat: 2024-T3 Aluminum Sheet

30
0,7(.025”) Thick - 36 required
(1.18”)

1170
Drill for pop rivets
(2.76”)

(46.063”)
25,4

(1”)
70

101
FIGHTER ULTRALIGHT -

(4”) Detail rear spar

Wing /Airfoil-Wing rib

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 Front mast DETAIL A DETAIL B

Fuselage Front end

Exploded view Boom ring

AN5 Bolts
Fuselage nose plate
Central Brackets
(upper) Fork

Central boom support

Bushing

Rear boom support

Fuselage nose plate

(lower)
Side member

Rear member 3

Front mast

Reinforcement
B
tube

Side member
2

Fork

Side member

1) Boom support bracket

2) Rear link plate

3) Wing strut link plate

Nose wheel
4) Landing gear mounting bracket

FIGHTER ULTRALIGHT -

Fuselage/Cockpit - Assembly Details

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 3900 (153.54”)
530(20.86”) 1170(46.06”)
Boom
650(25.60”) 1550(61.02”)
40(1.57”) 153(6.02”) Mat: 6063-T3 Aluminum Tube
463(18.23”)
Dia 101 (4”) 2 (.078) Wall Thk

90(3.54”) 240(9.45”) 437(17.20”)

Rear Boom

Central Plate 135(5.32”) Support

Mat: 2024-T3 Aluminum 5(.190”) thick - 1 Required
Mat: 6061-T6 Aluminum

R 180 (7.09”) 168(6.61”) tubes Dia 28 (1-1/8”)

R 150(5.90”)
1,5 (.058”) wall Thickness
Central Boom Support
2 Required (rigth/left)

Mat: 6061-T6 Aluminum

950 (37-7/16”)
tubes Dia 28 (1-1/8”) Central plate

1,5 (.058”) wall Thickness Riveted here

Dia 101(4”)
2 Required (rigth/left) 150(5.90”)
5
8
(.196”)
(.312”)

1360 (53.54”)
280(11.02”)

25,4(1”)
Dia 28
Fuselage Rear Member (1-1/8”)
Mat: same as side member-1 Reqd.

R 336 (13-1/4”)

Fuselage

74(2.91”)
Side Member

101 (4”) Mat: 2024-T3 Aluminum

tubes Dia 50,8 (2”) 1,65

700 (27-9/16”) (.065”) Wall Thickness

730 (28-3/4”)
2 Required (left/right)

1140(44.88”)

74(2.91”)
75(2.95”)

530(20.87”) R 336

(13-1/4”)
340(13.38”)

45(1.8”)
270(10.63”)

380(15”)
25,4(1”)
210(8.27”)

50.8(2”)
10(.39”)

Dia 8
155(6.10”)

300(11.81”) (.312”)
110(4.33”)

700 (27-9/16”)

101 101 101 101 101 101 101 101

FIGHTER ULTRALIGHT -
(4”) (4”) (4”) (4”) (4”) (4”) (4”) (4”)
35(1.38”)

1460(57.49”) 25,4(1”) Boom / Fuselage components

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 90 (3.54”) Rear Link Plate Fuselage Nose Plate
2(.080”) 2(.080”) Mat: 2024-T3 Aluminum 5 (.190”) Thick 2 Required
26
(1.02”) (Upper/Lower see instructions)
90(3.54”)

60(2.36”) 210 (8.27”)

90 (3.54”)
R 15
35(1.38”)

60(2.36”)
40(1.57”) (.60”)
Dia 8

(.312”) Dia 8

(.312”)

105(4.13”)

74(2.91”)
R11

(.43”)
Dia 8

(.312”)

Boom support bracket Mat: 2024-T3 Aluminum

Mat: Stainless Steel 2 (.080”) Thick -2 required 5 (.190”) Thick

4 Required
Wing Strut Link R 15

Mat: Stainless Steel -2 (0.80”) Thick -4 Required (.60”)

230 (9.05”)
Dia 8

Landing Gear Bracket !4(.55”) (.312”)

Dia 8
Mat: Stainless Steel
(.312”)
36(1.42”) 2 (.080”) Thick - 2 Required
71 (2.80”)

40(1.57”)

88 (3.46”)

Bending line

35(1.38”)
Dia 8
Bend 7º upward

92 (3.62”)
(.312”)

66 (2.60”)
R13
Dia12,7(1/2”)
60(2.36”) (.51”) 2(.080”)
26(1.02”)
90(3.54”)

20(.79”)

Pop rivet to boom

Bend around 4” tube and Boom Ring

80 (3.15”) 46 comform like this
Section
(1.81”) Mat: 2024-T3 Aluminum -

3 (.125”) Thick Dia 8

(.312”)
1 Required

57

(2-1/4”)
FIGHTER ULTRALIGHT -

340 (13.38”) Fuselage brackets

370 (14.57”) Plans delivery.com Designed and drawn by Osvaldo Durana 12

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FORK FRONT AXLE LANDING GEAR
425
Mat: Steel tube Front View
(16-3/4”)
62 (2.44”) Link from 2 (.83”) Thick
320
pedal
(12-5/8”)
attachment

point

FRONT FITTING
Mat: Steel
660 (26”)
Steel Tube 2,5 (.100”) Thick

Dia 22 (7/8”) Steel Tube

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

353 (13-7/8”) Dia 44 62 (2.44”)

165 (6-1/2”)
(1-3/4”)

Steel Tube

Dia 22 (7/8”)
90
Dia 12,7 (1/2”) 1,2 (.049”) Thick
(3.54”)
2 (.083”) Thick.

Welded Reinforcement

Attach Clevis Pin

Cotter pin

Steel Tube

Dia. 12,7 (1/2”)

Weld
REAR LANDING GEAR LEG
DETAIL
6 (.23”)
Drill for cotter pin
Axle housing
(each end)

To slide fit axle

Landing Gear Pivot Bracket Tap (see rear axle)

Mat: Steel 2 (.080”) Thick 30 (1.18”)

4 required
R 15 (.60”)
Brake Attachment Fitting

FORK HEAD Dia 22 (7/8”)

10 x 10 (.39” x .39”)
R 12 (.47”)
Mat: Steel 2,5 (.100”) Thick Dia 8 (.187”)

2 required

Welded steel washer

14 (.55”)
Dia 9,5 (3/8”) 3 (3/16”) Thick

52 (2.05”)

R 17 (.67”) 50,8
Dia. 12,7 (1/2”) Mat: Steel 2 (.080”) Thick
46 (1.81”)
30 (2”)
Fit to slide steel tubes 2 required
(1.18”)

12,7

(1/2”) FIGHTER ULTRALIGHT -

R. 17 (.67”)
134 (5.27”) Landing Gear
110 (4.33”)

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 Rear axle
Landing gear leg Mat: Steel - 2 Required

Dia 22 Dia 16
Dia 17
Dia 15
(.87”) (0.63”)
Brake positioning lug (.67”)
(.60”)

Thread Thread

25,4(1”)

2(.08”)
42(1.65”)

52(2.04”)

Brake plate 86(3.38”)

100(3.94”)

115(4.53”)
Rear axle

Spring

Brake arms Wheel

Brake drum

Inner wheel half

Bearing

Bearing housing
Bearing housing

Inner wheel half

Bearing

Control cable

A
N
A
R
U
D
O
D
L
A
V
S
O

Self locking nuts

Actuator arm

Slot for positioning lug

FIGHTER ULTRALIGHT -

Brake plate rear view Rear Wheel Assembly / Axle

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 Central Bracket

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

Dia 8
R 16
(.312”)
(.63”) Front Mast
Dia 8

Bending line
Aluminum Alloy tube Dia 32 (1-1/4”)

30(1.18”)
(.312”)

Central brackets 1,47 (.058) Wall Thk

A
N
A

Lenght: 1000 (39.37”)

R
U
D
O
D
L
A
V
S
O
Dia 11

(7/16”)

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

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 AILERONS

PEDALS

RUDDER

MIXER

CONTROL SIDE STICK

ELEVATOR

CONTROL CABLES

“TELEFLEX” TYPE

TAIL GROUP
FIGHTER ULTRALIGHT -

Control System

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Control Stick end Mat: Aluminum- 1 Required Control Arm 2(.090”) Pedal Mat: Aluminum sheet 3(.125) thick. -2 Required
Dia12,7(.5”)
*Dia 22(.87”) 12,7(1/2”) Mat: Steel - 1 Reqd.

12,7(1/2”)
130(5-1\8”)

* Diameter to fit snuggly in 1” dia. alum tube

** Insert in torque
101(4”)

35(1.38”)
tube before drill.

**5(.187”)
5(.187”)

47(1.85”)
8
weld

50(1.97”)
(.312”)

76(3”)
**5(.187”) 36(1.42”)
36(1.42”)

*Dia 22(.87”)
R

45(1.77”)

R 3 (.12”)
135(5.31”)

25,4 15(.60”)

60(2.36”)
12,7

(1/2”) (1”)
R15(.60”)
55(2.16”)

50,8(2”)

Aileron mixer Pedal Bushing

2(.090”)

12(.47”)
Mat:Steel 1 Rqrd.

5(.187”)
Dia 8 Mat: Grilon 4 Reqd.
R10
(.312”) 6,35(1/4”)
(.40”) 32(1.26”)

3,5(.137”)

12,7(1/2”)

60(2.36”)
20(.79”)

R13(.51”)

Dia 12,7(1/2”)
15(.60”)
10(.39”)

Push-Pull Barr end Mat: Aluminum- 1 Required 15(.60”) 26(1.02”)

285(11.22”)

130(5.19”)
36(1.42”) 8(.312”)
R13(.51”)
30

(1.18”) 38(1.50”)

60(2.36”)
*Dia22(.87”) 32(1-1/4”)
155 (6.10”)

Pedal Tang
47(1.85”) 40(1.60”)
R9(.35”) 6,35
104(4.09”)
15(.60”) (1/4”)
12(.48”)
R
R3(.12”)
10(.40”)

5
12,7(1/2”)

85(3.35”)
53(2.08”)
20(.79”) (.187”)
Weld

Dia. 5 5(.187”)
5(.187”)
(.187”) 25,4(1”)

12(.47”)
Bending lines
6(.24”)
Aileron Control Link 20(.79”) 11(.43”)

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

33(1.30”)
101 (4”)

170(6.70”) 140 (5.51”)

200 (7.87”)
Mat: S.Steel 2(.090”)

2 Required

FIGHTER ULTRALIGHT -

Rod End Bearings Tap tubes 1/4-28 thread or Control components

Male thread weld nut at both ends
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 WING STRUTS PEDALS

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 THROTTLE ASSY

streamlined steel tube.

FIGHTER ULTRALIGHT -

Wing Struts / Pedals Assembly

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ENGINE
Upper Bracket
Rubber mounts

Lower Bracket

Boom
Side Bracket

A
N
A
R
U
D
O
D
L
A
V
S
O

External Adapter

Inner Adapter

FIGHTER ULTRALIGHT -

Engine Mount Assembly

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 Engine Mount Side Bracket
Inner Adapter
Mat: Stainless Steel
Front View 1)
25,4 Mat: Aluminum 2 required
(1”) 3 (1/8”) Thick

135º 2 Required

135º

164 (6.46”)
According inner

diameter of

Boom Dia 8 60 (2.36”)

(5/16”)

135º Bending line

Dia 8

(5/16”) 15

65 (2.60”)
(.60”)

50,8

35(1.38”)
(2”)
R 10 (.39”)

Upper Bracket Boom 50.8 (2”)

Mat: Stainless Steel Aluminum tube Dia. 101 (4”)

3 (1/8”) Thick

2 Required

25.4 (1”)
1) R 10 (.39”)
Bending Line

Bending Line
2) 50,8 (2”)

50,8 (2”) NOTE

1) Diameter according Rubber

mounts

25,4 25,4
2) Diameter according en-
(1”)
3) R. 50,8 (2”)
60 (1”) 65
60 gine bolts
(2.36”) (2.36”) (2.56”)
273 (10-3/4”) 3) Length according engine Dia 8

(5/16”)
15

(.60”)
310 (12.20”)
25,4 25,4
(1”) (1”)

External Adapter
R 10
Bending Line

1) Mat: Aluminum 2 Required

Bending Line

(.39”)

50,8 (2”)

FIGHTER ULTRALIGHT -

65 65 Engine Mount Details

(2.56”) (2.56”)
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 220 220 230 220 240

(8.66”) (8.66”) (9.05”) (8.66”) (9.45”)

Polycarbonate windshield

450(17.72”)

340(13.38”)

230(9.05”)
(16.93”)
(12.40”)

430
(7.87”)

315

(984”)
200

250

(27.95”)
(21.65”)

(26.38”)
(17.72”)
(11.42”)

710
550

670
450
290

220 220 230 220 240 FIGHTER ULTRALIGHT -

(8.66”) (8.66”) (9.05”) (8.66”) (9.45”)

Cockpit Enclosure Three view

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Fighter Ultralight

Building guidelines

Welcome! You are about to get involve in one of Don’t for get the safety equipment like eye protec- Fasten the pulley and the support block to your two o three fillets of the thread should be vis-

the most rew arding projects that you can make tors, gloves, and respirators, always protect your worktable. ible.

with your own hands: eyes when drilling or working with power tools. Before cutting the tubes to be bend, be sure to If you want to assemble provisory the parts don’ t

An ultral ight aircraft that will bring you hours of Wel l, you got the space, the tools, get some raw allow material in ex cess. use self-locking nuts, but remember to replace

excitement and fun! material and start... Insert a plug into one of the tube ends, pour dry them when the assembly is definitive.

Before starting, take a moment to study the plans, sand inside the tube, tap gently to compact the

so you can understand the whole project and how Building the Tail group sand inside and place another plug on the other Use only stainless steel pop rivets; the alumi-

each part are made and assembled. This is the best starting point, especially to those end, the sand helps to avoid deformation in the num rivets will not have the str ength needed.

of you who need to gain practice in mechanical tube when it is bend.

Building process constructions. Once the tube is placed in the bending jig, secure The elevator is linked to the rudder wi th two

In the page #2 you can see the tai l group assem- it against the pulley with the support block and struts, which give strength to the tai l and help

It is recommendable to start with the tail group; bly and how it is fasten to the boom tube. start bending it very slowly, don’t try to bend it in to maintain the rudder and the elevator at 90

this will give you the experience needed to con- In page # 3 you ha ve all speci fications needed for one stroke, you will get wrinkles in the whole bend. degrees from each other. You will have to verify

tinue with more demanding or complex parts. building each element. The bending is made little by little moving the tube the length of each strut (they should be identi-

Begin with the fin, it’s the simplest part of the tai l forward in smal l increments till the curve is com- cal) measuring it once the tail group is finished

Your workshop and tools group. plete. and assembled.

This ultral ight can be build in an average home Bending the tubes Draw the desir e curve as a guide in the floor or in

garage, however more space will be required to If you don’ t have a tube bender, you can make a board and use it to check the progress of the The wing

assemble the complete aircraft. your own bending jig curve, placing the tube frequently against the draw- As you study the pages # 5; 6 and 7 you will

Put special attention to illumination of your work Using a hardwood pulley as depicted in the fol- ing. Try not to over-bend the tubes, it will be al- realize that the wing is not as complex as it ma y

area, working in a poorly illuminated area will lowing drawing. most impossible to un-bend. seem.

get you tired sooner and also prone to commi t The most difficult part of this operation is to ob- I recommend you to start with the compression

mistakes (some of them can be costly and some tain symmetric o equal curves as the ones required struts, these parts are made from 1” diameter
Support Block
dangerous) in the elevator, but don’ t dismay, wi th some prac- aluminum alloy tubes, cut them at the indicated

Keep your shop clean and organized, which will tice you will be able to create good curves. length and then make the stainless steel links

save you time and effort. After cutting the tubes to the r equired length use (page 8)

Equipment needed: a small round file or a deburring tool to clean the

A strong worktable is a definitive must. inside part of the tube. After cutting the spars and prior to start assem-

Measuring tools: bling the wing it is advisable to get a large board

Venier caliper, metallic ruler, measuring tape, The brackets are made from stainless steel sheet, where you can place and assembly the complete
Hardwood pulley
square, center punch, fel t point marker pen. this material is very tough and you will need well wing, since the dimension of each wing is more

Hand tools: sharpened drill bits to make the holes, make them large than the average worktables, you can en-

Hammer, hacksaw with several spare blades (with Diameter to fit tube smaller than the diameter required, then use a large the working surface of your table or bench,

different number of teeth per inch, to cut alumi- reamer in order to enlarge the holes at the right by placing a particle board over it.

num and steel) pop riveter, files (flat and r ound, size (the bolts should fit snuggly) It’s a good idea to nail wood blocks to the table
nd
2 and smooth cut) pl iers, aviation snips, com- Draw the contour of each bracket in the steel sheet, in order to secure the wing spars and other wing

bination wrenches, deburring tool, reamers. mark the holes with a punch marker, cut along the elements being added to the assembly.
Harwood pulley
Equip your worktable with a medium size vise to lines, clean the cuts with a file and bend as needed,

hold the parts been made. only then make the required holes. Page 5 shows the wing strut fi ttings bolted into

Drill and drill bits, a bench drill press can also be FIGHTER ULTRALIGHT
the spar with two reinforcement bushing,
- which

a great addition to your shop. In every assembly check the lengths of the bolts, are made from aluminum tubes.

once tighten with a nut (self locking nuts) only (Read Reinforcement bushing)
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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.
To cut the cable, wr ap 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 wi ll be use to
assemble the cables.
At the end of the cable, slide a short piece of rub-
ber hose.
Now slide the nicopress sleeve, mak e 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
Cable clamp
Nicopress Tool
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Now with the Nicopr ess Tool, you can compress num tubes that will support the boom (page 11)
the nicopress sleeve (usually making three grooves Rear boom support use an aluminum ring (page
along sleeve’s length), after that you can take away 12) to attach the boom (don’ t forget to rivet it
the cable clamp and the hose. to the boom)
The central boom support tubes (page 11) are
attached to the boom using steel brackets (page
Now you can start making the wing ribs, accord-
15 Central brackets)
ing to the drawing in page 9, to make all ribs equal,
Be careful when making the holes in the boom,
cut a pattern from a ½ inch wood slab and use it
have the tail group in place befor e attaching the
to bend the ribs.
chassis, this will help to keep the assembly
Cut the end of every rib as shown in page 9 to fi t
aligned.
over the main spar.
Finally measure and cut the front mast, you can
9 ribs are required for each half wing, and are
use a streamlined aluminum tube, and two stain-
riveted to the spars with the attaching fitting (made
less steel brackets to connect the mast wi th the
from aluminum sheet)
boom tube and the chassis.
Use a square to align each rib at 90 degrees from
the spars and perpendicular to the span.
Reinforcement bushings
When tubes are to be bolted, to avoid been flat-
Ailerons
tened when the bolt union is tighten, you can
Measure and cut to the required length the aile-
insert a short piece of hardwood or Nylon turned
ron spar from an aluminum tube diameter 38 (1-
to fit the inside diameter of the tube.
1/2”) mark the position of every aileron rib and
In some instances the reinforcement can be
drill a small hole through the spar, enlarge the
achieved using small aluminum tube as bush-
hole in the inboard face of the spar to accept the
ing.
aluminum rib (3/8” diameter tube) the trailing edge
e.g. for a 5/16” bolt (AN5) use as a bushing a 3/
tube is fastened to the ribs with pop rivets.
8” x .028 wall thickness tube
Once finished, place the aileron next to the wing
for a 7/16” bolt (AN7) you can use a ½” x .028
in the right position, mark the position of each
wal l thickness tube.
hinge, drill and bolt them in place.
Wing Spar (page 5)
Cockpit chassis
Now you can start wi th the cockpit chassis, cut-
ting and bending the side members, using the
bending method previously explained (you will
need to make another har dwood pulley to accept
the 2” diameter tube)
Cut the straight r ear member and make al l brack-
ets 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 card-
board as a template trace the lower plate which
will be a little longer in order to ac cept the fork. (it
could be convenient to have the fork already made)
FIGHTER ULTRALIGHT -
1) make the required holes through the spar
(use a drill bit = bolt size)
Once the chassis is made and all the parts bolted
together you can cut and bend the 1-1/8”
Plansalumi-
delivery.com Designed and drawn by Osvaldo Durana
 the brakes of this craft were taken from a small This is just a general guideline to help y ou to tackle this
Updated Mar-20-2001
motorcycle, you should search for some available project, more information about speci fically subjects like
Bushing
Bolt diameter holes
within your zone. welding, covering or working with composites/fiberglass
Diameter holes
can be find at your local l ibrary .

Abundant material and help can be found at the Ex-

Attaching the wing
perimental Aircraft Association (www.eaa.org)
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.

Control system

This aircraft emplo y a flexible push-pull control

system often called “Teleflex” which simplified the

task and it’s very r eliable.

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

spar) to insert the reinforcement bushings, com-

Covering
plete the assembly.
This aircraft is covered with Dacr on fabric (wings

and tail group, ev en there are good books that

Engine mount shows step by step how to cover your airplane we

The drawing in page 19 and 20 ar e self explana- are preparing an e-booklet that will show how to

tory, ac cording to the engine selected you will do it, i f you are interested, please send us a mai l.

have to vary the position of some holes (our pro-

totype used a Rotax engine) Fuel Tank

The design of this mount allows i t to slide over There are many models ready made, attach it to

the boom tube, don’t bolt to i t now, when the the central support tubes behind the seat.

airplane is finished you wi ll have to calculate the

weight and balance in order to place the center

of gravity in the right position (between 25% and A word of caution

30 % of the wing chord) allowing the engine to Warning! the set of plans and the instructions pr ovided

be able to slide forward or backward will help to here are for educational and recreational purposes only,

nor the designer neither Plans Del ivery.com can be re-

achieve the right C.G. position.
sponsible for injur es, property damages or ev en the

death to someone following the indications giv en here.

Landing gear
Flying could be a dangerous activity if is not done wi th
Page 13 shows al l the components of this sturdy
the expertise and knowledge required, we advise you
landing gear, almost all parts are made from steel
to take flying lessons prior to at tempt to fly in any aerial
tubing which are welded using oxyacetylene or
vehicle, been this experimental, ultralight or a home

TIG /MIG process, if you don’ t have the equip- built creation.

ment or the knowledge to do the welding find a Working wi th power tools, paints, solvents and related

welding shop in your area and get your gear chemicals also can be dangerous to people and prop-

erty if not done properly.

welded.
We advise you to use eye, body protection and f ollow
The EAA have several good books about welding
manufacturers recommendations. FIGHTER ULTRALIGHT -

that can guide you through this process.

Page 14 shows the wheel and br ake assembly,

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