Avion Ultrausor

FTGHTER OITRAITGHT -
PIans deI1Very.com 0es|gneo ano oraun o, Dsva|oo 0urana

Tnree V1ew
J
OSVALDO DURANA
OSVALDO DURANA
OETATI A
Hinge
Long Inner Bushing
Control Tee
Self locking nut
Ta1I Group assemIy
2
A
B
TATI BOOm
OETATI B
Inner Bushing
Pop Rivet
Dia. 25,4 (1)
25,4
(1)
Dia.6,35
(.25)
Bolt AN4
Bolt AN4
Clevis Pins
(use with safety lock pins)
Tail group Strut
Strut Lower Link
Strut Upper Link
5IruIs assemIy deIa1Is
Struts
(dotted lines)
Tail fittings
(to fit tube)
Short Inner Bushing
Contour to fit
elevator tube
Bolt AN4
AN Bolts
OSVALDO DURANA
PIans deI1Very.com 0es|gneo ano oraun o, Dsva|oo 0urana 3
Ta1I Group /Rudder
ROOOER .
Built with aluminum alloy tubes 6061-T6 - Diameter 1" - wall thickness .065"
406
(16)
203
(8)
Radius 127 (5) Rad.127
(5)
Dia.25,4
(1)
Dia.25,4
(1)
Dia. 19 (3/4) x
1,65 (.065)
Dia.19 (3/4) x
1,65 (.065)
558 (22)
Rad. 127 (5)
225 (8-7/8)
127
(5)
1
2
5
5

(
4
9
-
7
/
1
6
)
1
3
6
0

(
5
3
-
1
/
2
)
482
(19)
450
(17-3/4)
127 (5)
B B
B
B
Inner Bushing (short)
Hardwood bushing
COATROI TEE
2024-T3 Aluminum
5 (.190")Thickness
1 Required
Long Inner
Bushing
Dia 6,35
(.25)
Dia 6,35
(.25)
Rad. 9
(.35)
33 (1.30)
30 (1.81)
Rad.12,7
(.50)
Rad. 9 (.35)
TATI GROOP
FTTTTAG
Material
304 Stainless Steel
1,5 (.063") thickness
3 Required.
5HORT BO5HTAG
Material Aluminum
5 =(.197)
5 5
21,5
21,5 = (.846)
56
(2.20)
35
(1.38)
Dia. 6,35
(.25)
Rad. 11
(0.43)
92 (3.62)
114,5 (4.5)
B
e
n
d

l
i
n
e
Dia. To fit snuggly
into 25,4 (1) tubes
15 (.59)
36 (1.42)
22(.86)
12
(.47)
Tap for AN4
Bolt
Dia. 6,35 (.25)
60 (2.36)
30 (1.18)
12
(.47)
22 (.86)
Tap for AN4
Bolt
IOAG BO5HTAG
70
(2.76)
Dia. To fit
snuggly
into 25,4
(1) tubes
FTA
Ta1I Group /EIeVaIor
EIEVATOR .
Built with aluminum alloy tubes Quality 6061-T6 - Diameter 25,4 (1")
Wall thickness .065" 1185 (46-5/8)
600 (23-3/8)
130
(5.11)
127
(5)
4
2
5

(
1
6
-
3
/
4
)
203 (8)
Rad. 152 (6)
Dia. 19 (3/4) x 1,65 (.065)
Dia. 25,4 (1) x 1,65 (.065)
2500 (98.425)
101 (4)
R
27
625 (24-5/8)
R 225 (8-7/8)
301 (11-7/8)
R 152 (6)
930 (36-5/8)
B
B
B B
B
B
B
B
TATI GROOP 5TROT5 .
Aluminum tube Dia. 15 (5/8") x 1.65 (.065")
2 Required
Drill to fit Clevis pin Dia. 5 (3/16)
Length*
* Once the tail group is built and assembled, align it and
take the exact measurement of the struts
17 (.67)
1,5 (.060)
Dia 15 (5/8)
OPPER ITAK .
IOWER ITAK .
Stainless Steel
1,5 (.063) Thickness
1 Required
Dia. 6,35 (.25)
Dia.5 (3/16)
Dia. 5
(3/16)
Dia. 5 (3/16)
Dia. 5
(3/16)
25,4
(1)
50,8 (2)
30 (1.18)
Stainless Steel 1,5 (.063)
2 Required
Lower link attachment point
(see plan #2)
Lower link attachment point
(see plan #2)
W1ng /AssemIy
WTAG
W1ng T1p
W1ng RooI
A1Ieron
W1ng r1
W1ng r1 OeIa1I
W1ng 5par
Boom
W1ng 5par BracReI
Compress1on 5IruIs
.
Compression Strut
Tensor Cable
Link
Wing Spar
Wing strut fittings
Reinforcement Bushings
Bolts
FronI 5par
Rear 5par
+
,
-
*
A
See Details A, B, C, D, E and F on Page 6
Rib/Spar attachment
Turnbuckles
Turnbuckles
O
SVALDO
DURANA
W1ng /OeIa1Is
OETATI A
OETATI B
OETATI C
OETATI O
OETATI E
OETATI F
Aileron Rib
Aileron Tip Assembly
Aileron Spar
Aileron Spar Aluminum tube Dia.
38(1-1/2") 1,47 (.058") Wall Thk
Aileron Ribs Aluminum tube Dia. 9,5
(3/8") 0,90 (.035") Wall Thk
Trailing edge tube
aluminum Dia 15,8 (5/8")
1,47 (.058) Wall Thk
Aleron Root
Aluminum Sheet tip
Wing Tip
Wing Spar
5 Steel pop rivets
25,4 (1)
Wing Spar
Hardwood inner reinforcement
101(4") long.
4 Reqd.
Tensor cable
Link
Bolt
50,8
(2)
30
(1.18)
Plastic bushing
Reinforcement Bushing
Aileron Spar
Hardwood Bushing
Hinge
Aileron Control Arm
Hardwood insert
Wood screw
Steel pop rivet
W1ng /ConsIrucI1on OeIa1Is
W1ng .
Top view
200(7.87)
4520 (177.95)
2970 (117)
1320 (52)
550(21.65) 101 (4)
Wing root
1170 (46.06)
260(10.23)
Front Spar
W1ng T1p .
W1ng BracReIs .
640 (25.19)
4450 (175.20)
Trailing edge
20
200 (7.87)
Hinge
Wing tip bolted
to rear Spar
Wing Tip
W
i
n
g

r
i
b
s

(
9

p
e
r

w
i
n
g
)
C
o
m
p
r
e
s
s
i
o
n

s
t
r
u
t
T
e
n
s
o
r
c
a
b
le
C
o
m
p
r
e
s
s
i
o
n

s
t
r
u
t
54 (2.12)
54(2.12)
150(5.90)
B
e
n
d
i
n
g

l
i
n
e
Dia 8
(.312)
Dia11
(7/16)
Dia 8
(.312)
R 16
(.63)
1175(46.26)
R160
(6.30)
200(7.87)
150(5.90)
6061-T6 Aluminum Tube Dia
25,4(1)
2 Required
Mat: Stainless Steel - 2,5 (.100) Thick - 4 Required
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
Hinge
Hinge
Aileron
Hinge
Dia 15,8(5/8)
B
W1ng /ConsIrucI1on OeIa1Is
ATIEROA COATROI ARm
74
(2.91)
R 18
(.70)
70
(2.75)
Dia. 6,35 (.25)
R. 44 (1.73)
108
R. 9 (.35)
Dia. 6,35
(.25)
Material 2024-T3 aluminum Thickness 5 (.190") 2 Required
WTAG 5TROT FTTTTAG
2024-T3 Alum.
Thickness: 5 (.190")
8 Required
72
(2,83) R.16
(.63)
35
(1.38)
Dia. 6,36 (.25)
Dia. 8 (.312)
R.16 (.63)
R. 17
(.67)
WTAG 5TROT TTP
ITAK
73
(2.87)
87
(3.42)
Dia. 8 (.312)
R. 17
(.67)
4130 Steel
Thickness: 2 (.80")
8 Required
84 (3.30)
30 (1.18)
Dia. 8
(.312)
Dia. 3
(.12)
104 (4.09)
30 (1.18)
Dia.6,35
(.25)
Bend 90
upward by
dotted lines
Dia.6,35
(.25)
Dia.6,35
(.25)
Material :Stainless Steel
Thickness 1,5 (.063)
8 Required
R.15 (.60)
R.11 (.43)
5TROT TAAER ITAK
5PACER
80 (3.15)
50
(1.97)
50
(1.97)
Dia. 8 (.312)
R. 17
(.67)
Mat: Stainless Steel
Thickness: 2 (.080")
4 Required
R. 17
(.67)
8 (.31)
22 (.86)
Dia 8
(.312)
50
(1.97)
Chamfer Detail
2 (.080)
Mat: Steel
2 (.080") Thick.8 Required
HTAGE5
Mat: Stainless Steel 1,5 (.063") Thick
14 Required
23
(.90)
14
(.55)
20
(.80)
Dia 5 (.187)
R 8 (.31)
13
(.51)
ATIEROA TTP
25
9
(.35)
20
(.80)
38 (1.50)
R
53 (2.08)
232 (9.13)
112 (4.41)
180 (7.08)
Mat: Aluminum sheet 2024-T3 - 0,7 (.025") Thick - 2 Required
15 (.60)
Dia 3(.12)
30 (1.18)
5 (.20)
5 (3/16")
Bending lines
Bend around Dia 8 (.312)
to get a U shape
PIans deI1Very.com 0es|gneo ano oraun o, Dsva|oo 0urana P
W1ng /A1r1o1I-W1ng r1
7
2
(
2
.
8
3
5
)
1
1
5
(
4
.
5
2
7
)
1
3
0
(
5
.
1
1
8
)
1
4
2
(
5
.
5
9
0
)
9
5
(
3
.
7
4
0
)
1
5
0
(
5
.
9
0
5
)
1
5
8
(
6
.
2
2
0
)
1
6
3
(
6
.
4
1
7
)
1
6
7
(
6
.
5
7
5
)
1
7
0
(
6
.
6
9
3
)
1
7
2
(
6
.
7
7
2
)
1
7
1
(
6
.
7
3
2
)
1
7
1
(
6
.
7
3
2
)
1
8
9
(
7
.
4
4
1
)
1
6
8
(
6
.
6
1
4
)
1
6
5
(
6
.
4
9
6
)
1
6
1
(
6
.
3
3
8
)
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.
Mat: 2024-T3 Aluminum Sheet
0,7(.025") Thick - 36 required
1170
(46.063)
Detail rear spar
30
(1.18)
7
0
(
2
.
7
6
)
2
5
,
4
(
1
)
101
(4)
Drill for pop rivets
W1ng R1 AIIacnmenI
PIans deI1Very.com 0es|gneo ano oraun o, Dsva|oo 0urana JD
FuseIage/CocRp1I - AssemIy OeIa1Is
1
2
3
4
2
Side member
A
OETATI A
FuseIage FronI end
EXpIoded V1ew
Fork
Front mast
Side member
Bushing
Fuselage nose plate
(lower)
B
OETATI B
1) Boom support bracket
2) Rear link plate
3) Wing strut link plate
4) Landing gear mounting bracket
Boom ring
Fuselage nose plate
(upper)
Rear boom support
Central boom support
Front mast
Side member
Rear member
Fork
Nose wheel
AN5 Bolts
Central Brackets
Reinforcement
tube
PIans deI1Very.com 0es|gneo ano oraun o, Dsva|oo 0urana JJ
Boom / FuseIage componenIs
Boom
Mat: 6063-T3 Aluminum Tube
Dia 101 (4") 2 (.078) Wall Thk
Rear Boom
5upporI
Mat: 6061-T6 Aluminum
tubes Dia 28 (1-1/8")
1,5 (.058") wall Thickness
2 Required (rigth/left)
135(5.32)
R 150(5.90)
Dia 28
(1-1/8)
R 336
(13-1/4)
700 (27-9/16)
50.8(2)
CenIraI Boom 5upporI
tubes Dia 28 (1-1/8")
1,5 (.058") wall Thickness
2 Required (rigth/left)
R 180 (7.09)
9
5
0

(
3
7
-
7
/
1
6
)
1
3
6
0

(
5
3
.
5
4
)
R 336 (13-1/4)
101 (4)
700 (27-9/16)
FuseIage
51de memer
tubes Dia 50,8 (2") 1,65
(.065") Wall Thickness
2 Required (left/right)
FuseIage Rear memer
Mat: same as side member-1 Reqd.
25,4(1)
7
4
(
2
.
9
1
)
7
3
0

(
2
8
-
3
/
4
)
Dia 8
(.312)
25,4(1)
7
4
(
2
.
9
1
)
1140(44.88)
530(20.87)
380(15)
300(11.81)
35(1.38)
1460(57.49)
101
(4)
101
(4)
101
(4)
101
(4)
101
(4)
101
(4)
101
(4)
101
(4)
3
4
0
(
1
3
.
3
8
)
2
7
0
(
1
0
.
6
3
)
2
1
0
(
8
.
2
7
)
1
5
5
(
6
.
1
0
)7
5
(
2
.
9
5
)
1
1
0
(
4
.
3
3
)4
5
(
1
.
8
)
2
5
,
4
(
1
)
1
0
(
.
3
9
)
3900 (153.54)
530(20.86) 1170(46.06) 650(25.60)
90(3.54)
153(6.02)
40(1.57)
240(9.45)
1550(61.02)
463(18.23)
437(17.20)
CenIraI PIaIe
Mat: 2024-T3 Aluminum 5(.190) thick - 1 Required
168(6.61)
Dia 101(4)
150(5.90)
280(11.02)
8
(.312)
5
(.196)
Central plate
Riveted here
PIans deI1Very.com 0es|gneo ano oraun o, Dsva|oo 0urana J2
FuseIage racReIs
Boom supporI racReI
90 (3.54)
9
0

(
3
.
5
4
)
26
(1.02)
2(.080) 2(.080)
6
0
(
2
.
3
6
)
Dia 8
(.312)
40(1.57)
R11
(.43)
Mat: Stainless Steel 2 (.080") Thick -2 required
Rear I1nR PIaIe
5 (.190") Thick
4 Required
90(3.54)
60(2.36)
1
0
5
(
4
.
1
3
)
7
4
(
2
.
9
1
)
Dia 8
(.312)
35(1.38)
FuseIage Aose PIaIe
Mat: 2024-T3 Aluminum 5 (.190") Thick 2 Required
(Upper/Lower see instructions)
210 (8.27)
R 15
(.60)
R 15
(.60)
Dia 8
(.312)
Dia 8
(.312)
Dia 8
(.312)
Dia 8
(.312)
Dia 8
(.312)
!4(.55)
Dia12,7(1/2)
2
3
0

(
9
.
0
5
)
9
2

(
3
.
6
2
)
6
6

(
2
.
6
0
)
20(.79)
Iand1ng Gear BracReI
88 (3.46)
35(1.38)
26(1.02)
2(.080)
R13
(.51)
2 (.080) Thick - 2 Required
340 (13.38)
370 (14.57)
46
(1.81)
80 (3.15)
Boom R1ng
Mat: 2024-T3 Aluminum -
3 (.125") Thick
1 Required
W1ng 5IruI I1nR
Mat: Stainless Steel -2 (0.80") Thick -4 Required
7
1

(
2
.
8
0
)
4
0
(
1
.
5
7
)
60(2.36)
90(3.54)
36(1.42)
Bending line
Bend around 4 tube and
comform like this
57
(2-1/4)
Section
Pop rivet to boom
Bend 7 upward
Iand1ng Gear
FORK
62 (2.44)
Steel Tube
Dia 22 (7/8)
1,2 (.049) Thick
353 (13-7/8)
Dia 12,7 (1/2)
2 (.083) Thick.
Cotter pin
Weld
To slide fit axle
FORK HEAO
Mat: Steel 2,5 (.100") Thick
2 required
52 (2.05)
Dia. 12,7 (1/2)
Fit to slide steel tubes
134 (5.27)
R. 17 (.67)
Dia 9,5 (3/8)
R 15 (.60)
FROAT AXIE
Mat: Steel tube
2 (.83") Thick
165 (6-1/2)
FROAT FTTTTAG
Mat: Steel
2,5 (.100) Thick
Dia 44
(1-3/4)
62 (2.44)
90
(3.54)
OETATI
AXIe nous1ng
REAR IAAOTAG GEAR IEG
Iand1ng Gear P1VoI BracReI
Dia 8 (.187)
Welded steel washer
3 (3/16) Thick
110 (4.33)
30
(1.18)
46 (1.81)
Mat: Steel 2 (.080) Thick
4 required
R 12 (.47)
12,7
(1/2)
IAAOTAG GEAR
FronI V1ew
425
(16-3/4)
320
(12-5/8)
660 (26)
BraRe AIIacnmenI F1II1ng
50,8
(2)
Steel Tube
Dia 22 (7/8)
1,2 (.049) Thick
Dia 22 (7/8)
10 x 10 (.39 x .39)
14 (.55)
R 17 (.67)
6 (.23)
30 (1.18)
Steel Tube
Dia. 12,7 (1/2)
Welded Reinforcement
Steel Tube
Dia 22 (7/8)1,2 (.049) Thick
Mat: Steel 2 (.080) Thick
2 required
Drill for cotter pin
(each end)
Tap (see rear axle)
Attach Clevis Pin
Link from
pedal
attachment
point
Rear WneeI AssemIy / AXIe
BraRe pIaIe
Rear aXIe
5pr1ng
BraRe arms
BraRe drum
Tnner wneeI naI1
Bear1ng nous1ng
Bear1ng
Bear1ng
Bear1ng nous1ng
WneeI
Tnner wneeI naI1
5eI1 IocR1ng nuIs
BraRe pIaIe rear V1ew
ConIroI caIe
Iand1ng gear Ieg
Rear aXIe
Mat: Steel - 2 Required
Dia 15
(.60)
Dia 16
(0.63)
Dia 17
(.67)
Dia 22
(.87)
Thread Thread
25,4(1)
42(1.65)
52(2.04)
86(3.38)
100(3.94)
115(4.53)
2
(
.
0
8
)
Brake positioning lug
Slot for positioning lug
Actuator arm
O
S
V
A
LD
O
D
U
R
A
N
A
FuseIage /Ta1I Boom AssemIed
Torque tube
Aluminum Dia 25,4 (1")
500 (19.68") length
attached to longerons
by Nylon bushing
(allowing rotation)
Aluminum
tube Dia 25,4 (1")
300 (11.8") length
Control Arm
Side Stick
Central brackets
O
SVALDO
DURANA
CenIraI BracReI
Mat: Stainless steel - 2,5 (.100") Thick 2 Required
R 16
(.63)
Dia 8
(.312)
B
e
n
d
i
n
g

l
i
n
e
Dia 11
(7/16)
Dia 8
(.312)
30 (1.18)
62 (2.44)
3
0
(
1
.
1
8
)
Front Mast
Aluminum Alloy tube Dia 32 (1-1/4")
1,47 (.058) Wall Thk
Lenght: 1000 (39.37")
PIans deI1Very.com 0es|gneo ano oraun o, Dsva|oo 0urana J
ConIroI 5ysIem
TATI GROOP
ROOOER
EIEVATOR
ATIEROA5
COATROI 5TOE 5TTCK
PEOAI5
mTXER
COATROI CABIE5
TEIEFIEX TYPE
ConIroI componenIs
ConIroI 5I1cR end
*Dia 22(.87) 12,7(1/2)
5(.187)
R
R 3 (.12)
1
2
,
7
(
1
/
2
)
3
5
(
1
.
3
8
)
1
3
5
(
5
.
3
1
)
4
7
(
1
.
8
5
)
5
5
(
2
.
1
6
)
Dia 8
(.312)
R13(.51)
10(.39)
Mat: Aluminum- 1 Required
Pusn-PuII Barr end Mat: Aluminum- 1 Required
*

D
i
a
m
e
t
e
r

t
o

f
i
t

s
n
u
g
g
l
y

i
n

1

d
i
a
.

a
l
u
m

t
u
b
e
36(1.42)
*Dia22(.87)
47(1.85) 40(1.60)
104(4.09)
8(.312)
R13(.51)
12,7(1/2)
5(.187)
12(.48)
R
R3(.12)
1
0
(
.
4
0
)
A1Ieron ConIroI I1nR
Mat steel tube Dia 11(7/16") - 2 Required
Rod End Bearings Tap tubes 1/4-28 thread or
weld nut at both ends
170(6.70)
Male thread
ConIroI Arm
Mat: Steel - 1 Reqd.
2(.090)
Dia12,7(.5)
5
0
(
1
.
9
7
)
7
6
(
3
)
8
(.312)
weld
R15(.60)
**5(.187)
*
*
5
(
.
1
8
7
)
12,7
(1/2)
25,4
(1)
50,8(2)
*
D
i
a

2
2
(
.
8
7
)
** Insert in torque
tube before drill.
A1Ieron m1Xer
PedaI
PedaI Busn1ng
2(.090)
Mat:Steel 1 Rqrd.
6,35(1/4)
R10
(.40)
1
5
5

(
6
.
1
0
)
30
(1.18)
15(.60)
15(.60)
20(.79)
D
i
a

1
2
,
7
(
1
/
2
)
Weld
15(.60)
Mat: Grilon 4 Reqd.
32(1.26)
3
,
5
(
.
1
3
7
)
5
(
.
1
8
7
)
1
2
,
7
(
1
/
2
)
26(1.02)
38(1.50)
PedaI Tang
R9(.35)
Mat: S.Steel 2(.090)
2 Required
6,35
(1/4)
5
3
(
2
.
0
8
)
Dia. 5
(.187)
6(.24)
20(.79)
33(1.30)
Mat: Aluminum sheet 3(.125) thick. -2 Required
130(5-1\8)
101(4)
36(1.42)
45(1.77)
15(.60)
36(1.42)
6
0
(
2
.
3
6
)
6
0
(
2
.
3
6
)
6
0
(
2
.
3
6
)
32(1-1/4)
20(.79)
Bending lines
101 (4)
140 (5.51)
200 (7.87)
25,4(1)
11(.43) 1
2
(
.
4
7
)
5(.187)
5
(.187)
8
5
(
3
.
3
5
)
1
3
0
(
5
.
1
9
)
2
8
5
(
1
1
.
2
2
)
1
2
(
.
4
7
)
PIans deI1Very.com 0es|gneo ano oraun o, Dsva|oo 0urana JB
W1ng 5IruIs / PedaIs AssemIy
WTAG 5TROT5 PEOAI5
THROTTIE A55Y
FROAT 5PAR
REAR 5PAR
Steel tube to connect "teleflex"
Steel cable connect to fork
Bushings
Wing strut
fitting
Strut inner link
Spacers
Wing strut tip
Wing Strut
Wing strut are made from
streamlined steel tube.
Weld
Aluminum tubes
PIans deI1Very.com 0es|gneo ano oraun o, Dsva|oo 0urana JP
Eng1ne mounI AssemIy
EAGTAE
Rubber mounts
Opper BracReI
Iower BracReI
51de BracReI
Boom
EXIernaI AdapIer
Tnner AdapIer
OSVALDO DURANA
PIans deI1Very.com 0es|gneo ano oraun o, Dsva|oo 0urana 2D
Eng1ne mounI OeIa1Is
135
135
135
Eng1ne mounI
FronI V1ew
Opper BracReI
3 (1/8") Thick
2 Required
1)
2)
3)
25,4
(1)
60
(2.36)
25,4
(1)
60
(2.36)
50,8 (2)
R 10 (.39)
B
e
n
d
i
n
g

L
i
n
e
B
e
n
d
i
n
g

L
i
n
e
B
e
n
d
i
n
g

L
i
n
e
B
e
n
d
i
n
g

L
i
n
e
273 (10-3/4)
50,8 (2)
25,4
(1)
65
(2.56)
65
(2.56)
25,4
(1)
1)
R 10
(.39)
310 (12.20)
NOTE
1) Diameter according Rubber
mounts
2) Diameter according en-
gine bolts
3) Length according engine
R. 50,8 (2)
50,8 (2)
25.4 (1)
Dia 8
(5/16)
15
(.60)
65
(2.56)
EXIernaI AdapIer
Mat: Aluminum 2 Required
Tnner AdapIer
Mat: Aluminum 2 required
60 (2.36)
Dia 8
(5/16)
According inner
diameter of
Boom
15
(.60)
50,8
(2)
51de BracReI
3 (1/8") Thick
2 Required
25,4
(1)
Bending line
6
5

(
2
.
6
0
)
1
6
4

(
6
.
4
6
)
3
5
(
1
.
3
8
)
50.8 (2)
Dia 8
(5/16)
R 10 (.39)
1)
Boom
Aluminum tube Dia. 101 (4")
PIans deI1Very.com 0es|gneo ano oraun o, Dsva|oo 0urana 2J
CocRp1I EncIosure Tnree V1ew
220
(8.66)
220
(8.66)
220
(8.66)
230
(9.05)
240
(9.45)
2
0
0
(
7
.
8
7
)
3
1
5
(
1
2
.
4
0
)
4
3
0
(
1
6
.
9
3
)
2
5
0
(
9
8
4
)
4
5
0
(
1
7
.
7
2
)
2
3
0
(
9
.
0
5
)
220
(8.66)
220
(8.66)
220
(8.66)
230
(9.05)
240
(9.45)
2
9
0
(
1
1
.
4
2
)
4
5
0
(
1
7
.
7
2
)
5
5
0
(
2
1
.
6
5
)
6
7
0
(
2
6
.
3
8
)
7
1
0
(
2
7
.
9
5
)
3
4
0
(
1
3
.
3
8
)
Polycarbonate windshield
Hardwood pulley
Diameter to fit tube
Support Block
Harwood pulley
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
!t is recommendable to start with the tail group,
this will give you the experience needed to con-
tinue 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.
Neasuring 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 alumi-
num and steel) pop riveter, files (flat and round,
2
nd
and smooth cut) pliers, aviation snips, com-
bination 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 protec-
tors, 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.
!n the page #2 you can see the tail group assem-
bly and how it is fasten to the boom tube.
!n 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
!f you dont have a tube bender, you can make
your own bending jig
Using a hardwood pulley as depicted in the fol-
lowing drawing.
Fasten the pulley and the support block to your
worktable.
Before cutting the tubes to be bend, be sure to
allow material in excess.
!nsert 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 com-
plete.
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 draw-
ing. Try not to over-bend the tubes, it will be al-
most impossible to un-bend.
The most difficult part of this operation is to ob-
tain symmetric o equal curves as the ones required
in the elevator, but dont dismay, with some prac-
tice 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.
!n every assembly check the lengths of the bolts,
once tighten with a nut (self locking nuts) only
two o three fillets of the thread should be vis-
ible.
!f 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 alumi-
num 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 identi-
cal) 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.
! 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 assem-
bling 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 en-
large the working surface of your table or bench,
by placing a particle board over it.
!ts 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
are made from aluminum tubes.
(Read Reinforcement bushing)
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 1f8" x 1 x 19 steel cable that
can be galvanized or stainless.
(Diameter 1f8" x one strand of 19 wires)
Be sure to measure correctly each cable before
cutting them.
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.
At the end of the cable, slide a short piece of rub-
ber 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.
!n 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
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.
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 stain-
less steel brackets to connect the mast with the
boom tube and the chassis.
Reinforcement bushings
When tubes are to be bolted, to avoid been flat-
tened 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.
!n some instances the reinforcement can be
achieved using small aluminum tube as bush-
ing.
e.g. for a 5f16" bolt (AN5) use as a bushing a 3f
8" x .028 wall thickness tube
for a 7f16" bolt (AN7) you can use a " x .028
wall thickness tube.
Now you can start making the wing ribs, accord-
ing 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
Neasure and cut to the required length the aile-
ron spar from an aluminum tube diameter 38 (1-
1f2") 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 (3f8" 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.
Cockpit chassis
Now you can start with the cockpit chassis, cut-
ting 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 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 accept the fork. (it
could be convenient to have the fork already made)
Once the chassis is made and all the parts bolted
together you can cut and bend the 1-1f8" alumi-
1) make the required holes through the spar
(use a drill bit = bolt size)
Wing Spar (page 5)
Engine mount
The drawing in page 19 and 20 are self explana-
tory, according to the engine selected you will
have to vary the position of some holes (our pro-
totype 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
T!G fN!G process, if you dont have the equip-
ment 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 1+ shows the wheel and brake assembly,
2) enlarge the holes (only on this face of the
spar) to insert the reinforcement bushings, com-
plete the assembly.
Bolt diameter holes
Bushing
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.
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 wr / auIn
Warnng1 Ine seI / pIans an Ine nsIruIns prve
nere are /r euaInaI an rereaInaI purpses nI),
nr Ine esgner neIner PIans DeIver).m an De re-
spnsDIe /r n)ures, prperI) amages r even Ine
eaIn I smene /IIwng Ine naIns gven nere.
FI)ng uI De a angerus aIvI) / s nI ne wIn
Ine experIse an xnwIege requre, we avse )u
I Iaxe /I)ng Iessns prr I aIIempI I /I) n an) aeraI
venIe, Deen Ins expermenIaI, uIIraIgnI r a nme
DuII reaIn.
Wrxng wIn pwer IIs, panIs, sIvenIs an reIaIe
nemaIs aIs an De angerus I pepIe an prp-
erI) / nI ne prperI).
We avse )u I use e)e, D) prIeIn an /IIw
manu/aIurers remmenaIns.
This is just a general guideline to help you to tackle this
project, more information about specifically subjects like
welding, covering or working with compositesffiberglass
can be find at your local library .
Abundant material and help can be found at the Ex-
perimental Aircraft Association (www.eaa.org)
Updated Mar-20-2001

Avion Ultrausor

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Avion Ultrausor

Încărcat de

Drepturi de autor:

Formate disponibile

FTGHTER OITRAITGHT -

PIans deI1Very.com 0es|gneo ano oraun o, Dsva|oo 0urana

S-ar putea să vă placă și