OSVALDO DURANA

A
AN
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FIGHTER ULTRALIGHT -

Three view
Plans delivery.com Designed and drawn by Osvaldo Durana 1
 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
A

Struts assembly details

B
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Contour to fit Dia. 25,4 (1”)
Strut Upper Link LD
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NA
elevator tube (to fit tube)
25,4
Tail group Strut (1”)
Bolt AN4
Dia.6,35
(.25”)

Bolt AN4
Clevis Pins
(use with safety lock pins)
FIGHTER ULTRALIGHT -

Tail Group assembly

Strut Lower Link
Plans delivery.com Designed and drawn by Osvaldo Durana 2
 RUDDER . Dia. 6,35 (.25”) SHORT BUSHING
Built with aluminum alloy tubes 6061-T6 - Diameter 1” - wall thickness .065” Tap for AN4 Tap for AN4
Bolt Bolt 15 (.59”) Dia. To fit snuggly
Inner Bushing (short) into 25,4 (1”) tubes
Dia. To fit
406 203 snuggly 12
(16”) (8”) 12
into 25,4 (.47”) Material Aluminum
(.47”)
30 (1.18”)
22 (.86”) (1”) tubes 22(.86”)
B B 60 (2.36”) 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
FIN Material
Dia.25,4 Dia.25,4 304 Stainless Steel
(1”) (1”) Rad. 11
1,5 (.063”) thickness

Bend line
(0.43”) 35 56
Dia. 6,35 (1.38”) (2.20”) 3 Required.
Dia. 19 (3/4”) x (.25”)
1,65 (.065”)
Hardwood bushing
Dia.19 (3/4”) x

1255 (49-7/16”)
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

Plans delivery.com Designed and drawn by Osvaldo Durana 3
 ELEVATOR .
Built with aluminum alloy tubes Quality 6061-T6 - Diameter 25,4 (1”)
1185 (46-5/8”) 130 127 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 50,8 (2”) 17 (.67”) Dia 15 (5/8”)
(3/16”)
Dia. 5 (3/16”)
TAIL GROUP STRUTS .
1,5 (.060”) Aluminum tube Dia. 15 (5/8”) x 1.65 (.065”)
2 Required
Dia. 5 Length*
(3/16”)
30 (1.18”)
FIGHTER ULTRALIGHT -

Stainless Steel 1,5 (.063”) * Once the tail group is built and assembled, align it and Tail Group /Elevator
LOWER LINK . 2 Required take the exact measurement of the struts Plans delivery.com Designed and drawn by Osvaldo Durana 4
 WING
A
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
OS

Front Spar
VA
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Bolts
NA

Wing Spar FIGHTER ULTRALIGHT -

Wing /Assembly
Wing strut fittings
Plans delivery.com Designed and drawn by Osvaldo Durana 5
 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
Hardwood insert Steel pop rivet
Aileron Rib 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
Plans delivery.com Designed and drawn by Osvaldo Durana 6
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
Wing Tip ble

Compression strut
Wing ribs (9 per wing)
r ca
o
ns
Te
1170 (46.06”)

Hinge
Wing tip bolted
to rear Spar

200 (7.87”) Hinge Hinge Hinge

Aileron 260(10.23”)

Trailing edge
Dia 15,8(5/8”) 640 (25.19”)
20º
4450 (175.20”)

Wing Brackets .
6061-T6 Aluminum Tube Dia Mat: Stainless Steel - 2,5 (.100”) Thick - 4 Required
25,4(1”) R 16 Dia 8
(.63”) (.312”)
Wing Tip . R160 Dia 8
200(7.87”) 54 (2.12”)

Bending line
2 Required (6.30”) (.312”)

Dia11
150(5.90”) (7/16”)
54(2.12”)
1175(46.26”) 150(5.90”)

FIGHTER ULTRALIGHT -

Wing /Construction Details

Plans delivery.com Designed and drawn by Osvaldo Durana 7
 AILERON CONTROL ARM 80 (3.15”)
Bend around Dia 8 (.312”) WING STRUT FITTING
to get a “U” shape 72
R 18 74 R.16
(2,83”)
(.70”) (2.91”) R. 17 (.63”)
R. 9 (.35”) (.67”) R. 17 Dia. 6,36 (.25”) 2024-T3 Alum.
50 (.67”)
Thickness: 5 (.190”)
Dia. 6,35 (.25”) (1.97”)
35 8 Required
Dia. 8 (.312”)
(1.38”)
Dia. 8 (.312”)
70 R. 44 (1.73”)
(2.75”) STRUT INNER LINK 50
Mat: Stainless Steel
(1.97”)
Dia. 6,35 108º Thickness: 2 (.080”)
(.25”) 4 Required R.16 (.63”)

87
R. 17 WING STRUT TIP
(3.42”)
(.67”)
4130 Steel
50 Thickness: 2 (.80”)
Material 2024-T3 aluminum Thickness 5 (.190”) 2 Required (1.97”) Dia 8
8 Required
(.312”)
73
Dia 5 (.187”) 2 (.080”) (2.87”)
R 8 (.31”)
8 (.31”)
HINGES Chamfer Detail Dia. 8 (.312”)
Mat: Stainless Steel 1,5 (.063”) Thick 20 22 (.86”) R. 17
(.80”) 13 SPACER (.67”)
14 Required (.51”)
Mat: Steel
23 14
2 (.080”) Thick.8 Required
(.90”) (.55”)
25º
R.15 (.60”)

LINK
9
(.35”) Dia.6,35
(.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. 8
Dia 3(.12”) Bend 90º
20 (.312”)
(.80”) upward by
Bending lines 15 (.60”)
38 (1.50”) Dia. 3 dotted lines
Dia.6,35 (.12”)
(.25”)

R
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
 (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
Wing Rib Attachment riveted from leading edge spar to trailing edge spar.

Mat: 2024-T3 Aluminum Sheet

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

Drill for pop rivets 1170

(2.76”)

(46.063”)
25,4
(1”)
70

101 FIGHTER ULTRALIGHT -

(4”) Detail rear spar
Wing /Airfoil-Wing rib
Plans delivery.com Designed and drawn by Osvaldo Durana 9
 Front mast DETAIL A DETAIL B
Fuselage Front end
Exploded view Boom ring
AN5 Bolts
Fuselage nose plate
(upper) Fork Central Brackets

Central boom support

Bushing

Rear boom support

1
2

Fuselage nose plate

(lower) Side member

Rear member 3

Front mast

Reinforcement
B tube
A

Side member 2

4
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

Plans delivery.com Designed and drawn by Osvaldo Durana 10
 3900 (153.54”)
530(20.86”) 1170(46.06”) 650(25.60”) 1550(61.02”) Boom
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”) R 150(5.90”) tubes Dia 28 (1-1/8”)
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
2 Required (rigth/left) Dia 101(4”)
5 150(5.90”)
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”)
R 336
75(2.95”)

530(20.87”)
(13-1/4”)
340(13.38”)

45(1.8”)

380(15”)
270(10.63”)

25,4(1”)
210(8.27”)

Dia 8 50.8(2”)
10(.39”)
155(6.10”)

300(11.81”) (.312”)
110(4.33”)

700 (27-9/16”)

101
(4”)
101
(4”)
101
(4”)
101
(4”)
101
(4”)
101
(4”)
101
(4”)
101
(4”) 35(1.38”) FIGHTER ULTRALIGHT -

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

Plans delivery.com Designed and drawn by Osvaldo Durana 11
 90 (3.54”) Rear Link Plate Fuselage Nose Plate
2(.080”)
26
2(.080”) Mat: 2024-T3 Aluminum 5 (.190”) Thick 2 Required
(1.02”) 90(3.54”) (Upper/Lower see instructions)
60(2.36”) 210 (8.27”)

90 (3.54”)
35(1.38”) R 15

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
Dia 8
Landing Gear Bracket !4(.55”) (.312”)
Mat: Stainless Steel
(.312”)
36(1.42”) 2 (.080”) Thick - 2 Required
71 (2.80”)
40(1.57”)

88 (3.46”)
Bending line
Dia 8 35(1.38”) 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
1 Required (.312”)
57
(2-1/4”) FIGHTER ULTRALIGHT -

340 (13.38”) Fuselage brackets

370 (14.57”) Plans delivery.com Designed and drawn by Osvaldo Durana 12
FORK FRONT AXLE LANDING GEAR
425
Mat: Steel tube (16-3/4”) Front View
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
90 Dia 22 (7/8”)
Dia 12,7 (1/2”) 1,2 (.049”) Thick
(3.54”)
2 (.083”) Thick.
Welded Reinforcement
Cotter pin Attach Clevis Pin

Steel Tube
Dia. 12,7 (1/2”)
Weld REAR LANDING GEAR LEG
DETAIL 6 (.23”)
Axle housing Drill for cotter pin
(each end)
To slide fit axle
Landing Gear Pivot Bracket Tap (see rear axle)
Mat: Steel 2 (.080”) Thick 30 (1.18”)
R 15 (.60”) 4 required
Brake Attachment Fitting
FORK HEAD Dia 22 (7/8”)
R 12 (.47”) 10 x 10 (.39” x .39”)
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”) 46 (1.81”) Mat: Steel 2 (.080”) Thick
30 (2”)
Fit to slide steel tubes 2 required
(1.18”)
12,7
(1/2”) FIGHTER ULTRALIGHT -
R. 17 (.67”) Landing Gear
134 (5.27”) 110 (4.33”)
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
Brake positioning lug (.87”) (.67”) (0.63”)
(.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
AN
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U
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O
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SV
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Self locking nuts

Actuator arm

Slot for positioning lug

FIGHTER ULTRALIGHT -

Brake plate rear view 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 8
R 16
(.312”) Front Mast
(.63”) Dia 8
Aluminum Alloy tube Dia 32 (1-1/4”)

Bending line
(.312”)

30(1.18”)
Central brackets 1,47 (.058) Wall Thk
NA

D O
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Lenght: 1000 (39.37”)
V AL
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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

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
Control Stick end Mat: Aluminum- 1 Required Control Arm 2(.090”) Dia12,7(.5”) Pedal Mat: Aluminum sheet 3(.125) thick. -2 Required
*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”)
tube before drill.

35(1.38”)
5(.187”)

**5(.187”)
8

47(1.85”)
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”)

12,7 25,4 15(.60”)

60(2.36”)
(1/2”) (1”) R15(.60”)
55(2.16”)

50,8(2”)
Aileron mixer 2(.090”) Pedal Bushing
Mat:Steel 1 Rqrd.

12(.47”)
Dia 8 Mat: Grilon 4 Reqd.

5(.187”)
6,35(1/4”) R10
(.312”) (.40”) 32(1.26”)

3,5(.137”)

12,7(1/2”)

60(2.36”)
20(.79”)

R13(.51”)

Dia 12,7(1/2”)
10(.39”) 15(.60”)

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”) 155 (6.10”) 32(1-1/4”)
Pedal Tang
47(1.85”) 40(1.60”)
R9(.35”) 6,35
104(4.09”) (1/4”)
12(.48”) 15(.60”)
R
R3(.12”)
10(.40”)

12,7(1/2”) 5

85(3.35”)
20(.79”)

53(2.08”)
Weld (.187”)

5(.187”) Dia. 5 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”)
Mat: S.Steel 2(.090”) 200 (7.87”)
2 Required
FIGHTER ULTRALIGHT -
Rod End Bearings Tap tubes 1/4-28 thread or Control components
Male thread weld nut at both ends Plans delivery.com Designed and drawn by Osvaldo Durana 17
 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

Plans delivery.com Designed and drawn by Osvaldo Durana 18
ENGINE Upper Bracket
Rubber mounts

Lower Bracket

Side Bracket Boom

NA
RA
DU
D O
V AL
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External Adapter

Inner Adapter

FIGHTER ULTRALIGHT -

Engine Mount Assembly

Plans delivery.com Designed and drawn by Osvaldo Durana 19
 Engine Mount Side Bracket Inner Adapter
Mat: Stainless Steel
Front View 1) 25,4
(1”) 3 (1/8”) Thick
Mat: Aluminum 2 required
135º 2 Required

135º
According inner

164 (6.46”)
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”) 60
3) (1”) 65 R. 50,8 (2”)
60 gine bolts
(2.36”) (2.36”) (2.56”)
273 (10-3/4”) 3) Length according engine Dia 8
15 (5/16”)
(.60”)
310 (12.20”)
25,4 25,4
(1”) (1”)
External Adapter
R 10 1) Mat: Aluminum 2 Required
Bending Line

Bending Line

(.39”)
50,8 (2”)

FIGHTER ULTRALIGHT -

65 65 Engine Mount Details

(2.56”) (2.56”) Plans delivery.com Designed and drawn by Osvaldo Durana 20
 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
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 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.
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 alumi-
num and steel) pop riveter, files (flat and round,
nd
2 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.
Don’t 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.
In the page #2 you can see the tail group assem-
bly 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, it’s the simplest part of the tail
group.
Bending the tubes
If you don’t have a tube bender, you can make
your own bending jig
Using a hardwood pulley as depicted in the fol-
lowing drawing.
Support Block
Hardwood pulley
Diameter to fit tube
Harwood pulley
Fasten the pulley and the support block to your two o three fillets of the thread should be vis-
worktable. ible.
Before cutting the tubes to be bend, be sure to If you want to assemble provisory the parts don’t
allow material in excess. use self-locking nuts, but remember to replace
Insert a plug into one of the tube ends, pour dry them when the assembly is definitive.
sand inside the tube, tap gently to compact the
sand inside and place another plug on the other Use only stainless steel pop rivets; the alumi-
end, the sand helps to avoid deformation in the num rivets will not have the strength needed.
tube when it is bend.
Once the tube is placed in the bending jig, secure The elevator is linked to the rudder with two
it against the pulley with the support block and struts, which give strength to the tail and help
start bending it very slowly, don’t try to bend it in to maintain the rudder and the elevator at 90
one stroke, you will get wrinkles in the whole bend. degrees from each other. You will have to verify
The bending is made little by little moving the tube the length of each strut (they should be identi-
forward in small increments till the curve is com- cal) measuring it once the tail group is finished
plete. and assembled.
Draw the desire curve as a guide in the floor or in
a board and use it to check the progress of the The wing
curve, placing the tube frequently against the draw- As you study the pages # 5; 6 and 7 you will
ing. Try not to over-bend the tubes, it will be al- realize that the wing is not as complex as it may
most impossible to un-bend. seem.
The most difficult part of this operation is to ob- I recommend you to start with the compression
tain symmetric o equal curves as the ones required struts, these parts are made from 1” diameter
in the elevator, but don’t dismay, with some prac- aluminum alloy tubes, cut them at the indicated
tice you will be able to create good curves. length and then make the stainless steel links
After cutting the tubes to the required length use (page 8)
a small round file or a deburring tool to clean the
inside part of the tube. After cutting the spars and prior to start assem-
bling the wing it is advisable to get a large board
The brackets are made from stainless steel sheet, where you can place and assembly the complete
this material is very tough and you will need well wing, since the dimension of each wing is more
sharpened drill bits to make the holes, make them large than the average worktables, you can en-
smaller than the diameter required, then use a large the working surface of your table or bench,
reamer in order to enlarge the holes at the right by placing a particle board over it.
size (the bolts should fit snuggly) It’s a good idea to nail wood blocks to the table
Draw the contour of each bracket in the steel sheet, in order to secure the wing spars and other wing
mark the holes with a punch marker, cut along the elements being added to the assembly.
lines, clean the cuts with a file and bend as needed,
only then make the required holes. Page 5 shows the wing strut fittings bolted into
FIGHTER ULTRALIGHT
the spar with two reinforcement bushing, - which
In every assembly check the lengths of the bolts, are made from aluminum tubes.
once tighten with a nut (self lockingPlans only (Read Reinforcement
nuts)delivery.com bushing)
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.
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.
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
Now with the Nicopress Tool, you can compress
the nicopress sleeve (usually making three grooves
along sleeve’s length), after that you can take away
the cable clamp and the hose.
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 ½ 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 aile-
ron spar from an aluminum tube diameter 38 (1-
1/2”) 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.
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) FIGHTER ULTRALIGHT -
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
num tubes that will support the boom (page 11)
Rear boom support use an aluminum ring (page
12) to attach the boom (don’t 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.
In some instances the reinforcement can be
achieved using small aluminum tube as bush-
ing.
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 ½” x .028
wall thickness tube.
Wing Spar (page 5)
1) make the required holes through the spar
(use a drill bit = bolt size)

Bushing
Bolt diameter holes
Diameter holes
2) enlarge the holes (only on this face of the
spar) to insert the reinforcement bushings, com-
plete the assembly.
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, don’t 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 don’t 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 14 shows the wheel and brake assembly,
the brakes of this craft were taken from a small This is just a general guideline to help you to tackle this
Updated Mar-20-2001
motorcycle, you should search for some available project, more information about specifically subjects like
within your zone. welding, covering or working with composites/fiberglass
can be find at your local library .
Attaching the wing Abundant material and help can be found at the Ex-
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 employ a flexible push-pull control
system often called “Teleflex” which simplified the
task and it’s 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 re-
sponsible 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 prop-
erty 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