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Fighter Ultralight Plans
Fighter Ultralight Plans
OS
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FIGHTER ULTRALIGHT
Three view
Plans delivery.com Designed and drawn by Osvaldo Durana
DETAIL A
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
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NA
Contour to fit
elevator tube
25,4
(1)
Dia.6,35
(.25)
Bolt AN4
Clevis Pins
(use with safety lock pins)
Strut Lower Link
FIGHTER ULTRALIGHT
RUDDER .
SHORT BUSHING
406
(16)
12
(.47)
22 (.86)
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)
36 (1.42)
LONG BUSHING
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.
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
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)
B
B
203 (8)
2500 (98.425)
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.5 (3/16)
17 (.67)
50,8 (2)
Dia. 5 (3/16)
Dia 15 (5/8)
1,5 (.060)
2 Required
Length*
30 (1.18)
LOWER LINK .
FIGHTER ULTRALIGHT
WING
A
Wing Spar
Wing Tip
Aileron
Wing rib
Boom
Compression Struts
*
See Details A, B, C, D, E and F on Page 6
Rib/Spar attachment
Compression Strut
Reinforcement Bushings
Link
OS
Bolts
VA
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NA
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
Hardwood insert
Aileron Rib
DETAIL F
Wing Tip
Aleron Root
DETAIL D
Wing Spar
Aileron Spar
Reinforcement Bushing
Plastic bushing
25,4 (1)
DETAIL E
Wing Spar
Hinge
Hardwood Bushing
50,8
(2)
Tensor cable
30
(1.18)
Link
Bolt
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)
200 (7.87)
ble
ca
r
o
ns
Te
Hinge
Compression strut
Hinge
Compression strut
Wing Tip
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 .
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
74
(2.91)
R. 17
(.67)
R. 9 (.35)
50
(1.97)
80 (3.15)
R. 17
(.67)
2024-T3 Alum.
Thickness: 5 (.190)
8 Required
35
(1.38)
Dia. 8 (.312)
50
(1.97)
108
Dia. 6,35
(.25)
R.16
(.63)
Dia. 8 (.312)
R. 44 (1.73)
72
(2,83)
R.16 (.63)
87
(3.42)
R. 17
(.67)
4130 Steel
Thickness: 2 (.80)
8 Required
50
(1.97) Dia 8
(.312)
Dia 5 (.187)
HINGES
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)
8 Required
232 (9.13)
AILERON TIP
FIGHTER ULTRALIGHT
161
(6.338)
165
(6.496)
168
(6.614)
189
(7.441)
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.
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)
FIGHTER ULTRALIGHT
DETAIL A
Fuselage Front end
Exploded view
Front mast
DETAIL B
Boom ring
AN5 Bolts
Central Brackets
Fork
Side member
Rear member
Front mast
Reinforcement
tube
B
A
Side member
2
4
Fork
Nose wheel
Side member
FIGHTER ULTRALIGHT
10
40(1.57)
530(20.86)
153(6.02)
3900 (153.54)
650(25.60)
1170(46.06)
Boom
1550(61.02)
463(18.23)
90(3.54)
240(9.45)
437(17.20)
Central Plate
135(5.32)
Rear Boom
Support
168(6.61)
R 150(5.90)
Central plate
Riveted here
5
(.196)
Dia 101(4)
8
(.312)
150(5.90)
1360 (53.54)
950 (37-7/16)
280(11.02)
25,4(1)
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
11
90(3.54)
60(2.36)
74(2.91)
105(4.13)
Dia 8
(.312)
R 15
(.60)
Dia 8
(.312)
!4(.55)
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)
210 (8.27)
35(1.38)
40(1.57)
R11
(.43)
71 (2.80)
230 (9.05)
2(.080)
60(2.36)
90 (3.54)
Dia 8
(.312)
26
(1.02)
90 (3.54)
2(.080)
20(.79)
Pop rivet to boom
80 (3.15)
46
(1.81)
Section
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
320
(12-5/8)
FRONT FITTING
Mat: Steel
Steel Tube
Dia 22 (7/8)
1,2 (.049) Thick
660 (26)
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)
Welded Reinforcement
Cotter pin
Weld
Steel Tube
Dia. 12,7 (1/2)
DETAIL
Axle housing
To slide fit axle
6 (.23)
30 (1.18)
4 required
R 15 (.60)
FORK HEAD
R 12 (.47)
134 (5.27)
Dia 8 (.187)
10 x 10 (.39 x .39)
R. 17 (.67)
14 (.55)
3 (3/16) Thick
52 (2.05)
R 17 (.67)
30
(1.18)
12,7
(1/2)
110 (4.33)
50,8
(2)
2 required
FIGHTER ULTRALIGHT
Landing Gear
Plans delivery.com Designed and drawn by Osvaldo Durana
13
Rear axle
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
Bearing
Control cable
Actuator arm
SV
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FIGHTER ULTRALIGHT
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
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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
15
AILERONS
PEDALS
RUDDER
MIXER
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)
6,35
(1/4)
20(.79)
33(1.30)
170(6.70)
Mat: S.Steel 2(.090)
2 Required
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)
Dia 12,7(1/2)
20(.79)
32(1.26)
60(2.36)
R10
(.40)
130(5.19)
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
5(.187)
Pedal
Dia12,7(.5)
53(2.08)
5(.187)
**5(.187)
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)
*Dia 22(.87)
12,7(1/2)
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
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
18
ENGINE
Rubber mounts
Upper Bracket
Lower Bracket
Side Bracket
OS
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Boom
NA
External Adapter
Inner Adapter
FIGHTER ULTRALIGHT
19
Side Bracket
Engine Mount
Front View
1)
135
Inner Adapter
25,4
(1)
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
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)
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)
According inner
diameter of
Boom
50,8 (2)
65
(2.56)
FIGHTER ULTRALIGHT
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
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
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.
Bushing
Diameter holes
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