Fighter Ultralight Plans

OSVALDO DURANA

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FIGHTER ULTRALIGHT

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

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DETAIL A

Long Inner Bushing

AN Bolts

TAIL BOOM

Bolt AN4 Hinge Short Inner Bushing

Tail fittings Struts (dotted lines)

Control Tee Self locking nut

DETAIL B Inner Bushing

Pop Rivet

A Struts assembly details

B OS

Strut Upper Link

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Dia. 25,4 (1”)

Contour to fit elevator tube

25,4 (1”)

Tail group Strut Bolt AN4

(to fit tube)

Dia.6,35 (.25”)

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

FIGHTER ULTRALIGHT

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Tail Group assembly Plans delivery.com Designed and drawn by Osvaldo Durana

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RUDDER .

SHORT BUSHING

Dia. 6,35 (.25”)

Inner Bushing (short) 203 (8”)

406 (16”)

12 (.47”) 22 (.86”)

B

B

Tap for AN4 Bolt

Tap for AN4 Bolt

30 (1.18”) 60 (2.36”)

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

5 21,5 Dia.25,4 (1”)

Dia.25,4 (1”)

12 (.47”)

Material Aluminum

22(.86”)

5 =(.197”) 21,5 = (.846”)

Rad.127 (5”)

558 (22”)

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

36 (1.42”)

LONG BUSHING

Radius 127 (5”)

15 (.59”)

TAIL GROUP FITTING

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FIN Rad. 11 (0.43”)

Dia. 19 (3/4”) x 1,65 (.065”)

35 (1.38”) Dia. 6,35 (.25”)

Bend line

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

56 (2.20”)

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

Rad. 127 (5”)

225 (8-7/8”)

Dia.19 (3/4”) x 1,65 (.065”)

92 (3.62”) 114,5 (4.5”)

1360 (53-1/2”)

1255 (49-7/16”)

Hardwood bushing

Rad. 9 (.35”)

Long Inner Bushing 127 (5”)

B 482 (19”)

70 (2.76”) Dia 6,35 (.25”)

Rad.12,7 (.50”) Dia 6,35 (.25”)

CONTROL TEE 33 (1.30”)

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

30 (1.81”)

B

127 (5”)

Rad. 9 (.35”) 450 (17-3/4”)

FIGHTER ULTRALIGHT

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Tail Group /Rudder Plans delivery.com Designed and drawn by Osvaldo Durana

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ELEVATOR . 127 (5”)

130 (5.11”)

1185 (46-5/8”)

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

425 (16-3/4”)

600 (23-3/8”)

Lower link attachment point (see plan #2)

B

B B

Dia. 19 (3/4”) x 1,65 (.065”)

Rad. 152 (6”)

Dia. 25,4 (1”) x 1,65 (.065”)

B

203 (8”)

B

B

B

B

2500 (98.425”)

Lower link attachment point (see plan #2)

101 (4”) R

301 (11-7/8”)

R 152 (6”) 27º 625 (24-5/8”)

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

25,4 (1”) Dia. 5 (3/16”)

Dia. 5 (3/16”)

R 225 (8-7/8”)

Dia. 6,35 (.25”) 930 (36-5/8”)

Dia.5 (3/16”) 17 (.67”)

50,8 (2”) Dia. 5 (3/16”)

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

Dia 15 (5/8”)

TAIL GROUP STRUTS .

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

1,5 (.060”)

2 Required

Length* 30 (1.18”)

LOWER LINK .

Stainless Steel 1,5 (.063”) 2 Required

* Once the tail group is built and assembled, align it and take the exact measurement of the struts

FIGHTER ULTRALIGHT

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Tail Group /Elevator Plans delivery.com Designed and drawn by Osvaldo Durana

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WING A

Wing Spar Wing Tip

Wing Spar Bracket

Aileron Wing rib

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

Wing rib Detail Turnbuckles +

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Rib/Spar attachment Compression Strut Reinforcement Bushings Link OS

Bolts

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Wing strut fittings

Turnbuckles

Tensor Cable

Rear Spar Wing Root

Front Spar Wing Spar

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FIGHTER ULTRALIGHT

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

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DETAIL A

DETAIL B

DETAIL C

Aileron Ribs Aluminum tube Dia. 9,5 (3/8”) 0,90 (.035”) Wall Thk Trailing edge tube aluminum Dia 15,8 (5/8”) Aileron Spar Aluminum tube Dia. 1,47 (.058) Wall Thk 38(1-1/2”) 1,47 (.058”) Wall Thk

Aluminum Sheet tip Aileron Spar Wood screw

Steel pop rivet

Hardwood insert

Aileron Rib

DETAIL F

Aileron Tip Assembly

Wing Tip

Aleron Root

DETAIL D

Wing Spar Aileron Spar

Reinforcement Bushing Plastic bushing

25,4 (1”)

DETAIL E

5 Steel pop rivets

Wing Spar

Hinge Hardwood Bushing

50,8 (2”)

Tensor cable

30 (1.18”)

Link Bolt

Hardwood inner reinforcement 101(4”) long. 4 Reqd.

Aileron Control Arm

FIGHTER ULTRALIGHT

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

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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”)

Wing root

4520 (177.95”) 2970 (117”)

1320 (52”) 550(21.65”)

Wing tip bolted to rear Spar

200 (7.87”)

ble ca r o ns Te

Hinge

Compression strut

Hinge

Compression strut

Wing Tip

Wing ribs (9 per wing)

Front Spar

Trailing edge 20º

1170 (46.06”)

Hinge

Aileron

101 (4”)

Hinge

Dia 15,8(5/8”)

260(10.23”)

640 (25.19”)

4450 (175.20”)

Wing Brackets .

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

6061-T6 Aluminum Tube Dia 25,4(1”) R160 (6.30”)

2 Required

200(7.87”)

150(5.90”) 1175(46.26”)

Dia 8 (.312”)

54 (2.12”)

Dia11 (7/16”)

Bending line

Wing Tip .

Dia 8 (.312”)

R 16 (.63”)

54(2.12”) 150(5.90”)

FIGHTER ULTRALIGHT

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

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AILERON CONTROL ARM R 18 (.70”)

74 (2.91”)

R. 17 (.67”)

R. 9 (.35”)

50 (1.97”)

Dia. 6,35 (.25”) 70 (2.75”)

Bend around Dia 8 (.312”) to get a “U” shape

80 (3.15”)

R. 17 (.67”)

STRUT INNER LINK

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

(1.38”)

Dia. 8 (.312”)

50 (1.97”)

Mat: Stainless Steel Thickness: 2 (.080”) 4 Required

108º

Dia. 6,35 (.25”)

R.16 (.63”)

Dia. 6,36 (.25”)

Dia. 8 (.312”)

R. 44 (1.73”)

WING STRUT FITTING

72 (2,83”)

R.16 (.63”) 87 (3.42”)

R. 17 (.67”)

WING STRUT TIP

4130 Steel Thickness: 2 (.80”) 8 Required

50 (1.97”) Dia 8

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

(.312”)

Dia 5 (.187”)

HINGES

Mat: Stainless Steel 1,5 (.063”) Thick 14 Required

20 (.80”)

2 (.080”)

Chamfer Detail

8 (.31”)

SPACER

13 (.51”)

23 (.90”)

25º

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 90º upward by dotted lines

Dia. 3 (.12”)

R 53 (2.08”)

5 (3/16”)

104 (4.09”)

Material :Stainless Steel Thickness 1,5 (.063”)

8 Required

232 (9.13”)

AILERON TIP

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

FIGHTER ULTRALIGHT

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

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161 (6.338”)

165 (6.496”)

168 (6.614”)

189 (7.441”)

Mat: 2024-T3 Aluminum Sheet 0,7(.025”) Thick - 36 required

Drill for pop rivets

101 (4”)

1170 (46.063”)

25,4 (1”)

70 (2.76”)

171 (6.732”)

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

Wing Rib Attachment 30 (1.18”)

171 (6.732”)

172 (6.772”)

170 (6.693”)

167 (6.575”)

163 (6.417”)

158 (6.220”)

150 (5.905”)

142 (5.590”)

130 (5.118”)

115 (4.527”)

95 (3.740”) 72 (2.835”)

25,4 (1”)

Detail rear spar

FIGHTER ULTRALIGHT

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Wing /Airfoil-Wing rib Plans delivery.com Designed and drawn by Osvaldo Durana

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DETAIL A Fuselage Front end Exploded view

Front mast

DETAIL B Boom ring AN5 Bolts

Fuselage nose plate (upper)

Central Brackets

Fork

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

Side member Rear member

3

Front mast Reinforcement tube

B A Side member

2 4

Fork

Nose wheel

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

Side member

FIGHTER ULTRALIGHT

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Fuselage/Cockpit - Assembly Details Plans delivery.com Designed and drawn by Osvaldo Durana

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40(1.57”)

530(20.86”) 153(6.02”)

3900 (153.54”) 650(25.60”)

1170(46.06”)

Boom

1550(61.02”)

Mat: 6063-T3 Aluminum Tube Dia 101 (4”) 2 (.078) Wall Thk

463(18.23”)

90(3.54”)

240(9.45”)

437(17.20”)

Central Plate

135(5.32”)

Mat: 2024-T3 Aluminum 5(.190”) thick - 1 Required R 180 (7.09”)

Rear Boom Support

168(6.61”)

Mat: 6061-T6 Aluminum tubes Dia 28 (1-1/8”) 1,5 (.058”) wall Thickness 2 Required (rigth/left)

R 150(5.90”)

Central plate Riveted here

5 (.196”)

Dia 101(4”) 8 (.312”)

150(5.90”) 1360 (53.54”)

Mat: 6061-T6 Aluminum tubes Dia 28 (1-1/8”) 1,5 (.058”) wall Thickness 2 Required (rigth/left)

950 (37-7/16”)

Central Boom Support

280(11.02”)

Fuselage Rear Member

25,4(1”)

Mat: same as side member-1 Reqd. 74(2.91”)

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

101 (4”) 700 (27-9/16”)

101 (4”)

101 (4”)

101 (4”)

75(2.95”)

101 (4”)

101 (4”)

101 (4”)

101 (4”)

380(15”)

10(.39”)

25,4(1”)

45(1.8”)

530(20.87”)

110(4.33”)

155(6.10”)

210(8.27”)

270(10.63”)

340(13.38”)

1140(44.88”)

101 (4”)

300(11.81”)

1460(57.49”)

35(1.38”)

Dia 8 (.312”)

74(2.91”) 730 (28-3/4”)

R 336 (13-1/4”)

Dia 28 (1-1/8”)

R 336 (13-1/4”)

50.8(2”)

700 (27-9/16”)

25,4(1”)

FIGHTER ULTRALIGHT

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Boom / Fuselage components Plans delivery.com Designed and drawn by Osvaldo Durana

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90(3.54”) 60(2.36”)

74(2.91”)

105(4.13”)

Dia 8 (.312”)

Boom support bracket

R 15 (.60”)

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

Mat: 2024-T3 Aluminum 5 (.190”) Thick 4 Required

Landing Gear Bracket

Dia 8 (.312”)

!4(.55”)

Mat: Stainless Steel 2 (.080”) Thick - 2 Required

36(1.42”)

Dia 8 (.312”)

Dia 8 35(1.38”) (.312”) R13 (.51”)

60(2.36”) 90(3.54”)

26(1.02”)

Bend 7º upward

Dia12,7(1/2”)

2(.080”)

92 (3.62”)

88 (3.46”)

Bending line

66 (2.60”)

40(1.57”)

R 15 (.60”) Dia 8 (.312”)

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

Wing Strut Link

210 (8.27”)

35(1.38”)

40(1.57”)

R11 (.43”)

71 (2.80”)

Mat: 2024-T3 Aluminum 5 (.190”) Thick 2 Required (Upper/Lower see instructions)

230 (9.05”)

2(.080”)

60(2.36”)

90 (3.54”)

Dia 8 (.312”)

26 (1.02”)

Fuselage Nose Plate

Rear Link Plate

90 (3.54”)

2(.080”)

20(.79”) Pop rivet to boom

80 (3.15”)

46 (1.81”)

Section

Bend around 4” tube and comform like this

57 (2-1/4”)

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

Dia 8 (.312”)

FIGHTER ULTRALIGHT

340 (13.38”) 370 (14.57”)

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

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FORK

FRONT AXLE

62 (2.44”)

Link from pedal attachment point

Mat: Steel tube 2 (.83”) Thick

320 (12-5/8”)

FRONT FITTING

Mat: Steel

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

660 (26”)

2,5 (.100”) Thick

353 (13-7/8”)

LANDING GEAR Front View

425 (16-3/4”)

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

Dia 44 (1-3/4”)

165 (6-1/2”)

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

90 (3.54”)

Dia 12,7 (1/2”) 2 (.083”) Thick.

Welded Reinforcement

Attach Clevis Pin

Cotter pin Weld

Steel Tube Dia. 12,7 (1/2”)

REAR LANDING GEAR LEG

DETAIL Axle housing To slide fit axle

6 (.23”)

Drill for cotter pin (each end)

Landing Gear Pivot Bracket

30 (1.18”)

Mat: Steel 2 (.080”) Thick

4 required

R 15 (.60”)

FORK HEAD

R 12 (.47”)

Mat: Steel 2,5 (.100”) Thick 2 required Dia 9,5 (3/8”) Dia. 12,7 (1/2”) Fit to slide steel tubes

134 (5.27”)

Brake Attachment Fitting Dia 22 (7/8”)

Dia 8 (.187”)

10 x 10 (.39” x .39”)

Welded steel washer 46 (1.81”)

R. 17 (.67”)

14 (.55”)

3 (3/16”) Thick

52 (2.05”)

Tap (see rear axle)

R 17 (.67”)

30 (1.18”)

12,7 (1/2”) 110 (4.33”)

50,8 (2”)

Mat: Steel 2 (.080”) Thick

2 required

FIGHTER ULTRALIGHT

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

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Rear axle

Landing gear leg

Mat: Steel - 2 Required Dia 22 Dia 17 Dia 16 Dia 15 (.87”) (.67”) (0.63”) (.60”)

Brake positioning lug Thread

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

Brake plate Rear axle Spring Brake arms

2(.08”)

Thread

Wheel

Brake drum Inner wheel half

Bearing Bearing housing

Bearing housing

Inner wheel half

Bearing Control cable

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Actuator arm

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Self locking nuts

Slot for positioning lug

Brake plate rear view

FIGHTER ULTRALIGHT

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Rear Wheel Assembly / Axle Plans delivery.com Designed and drawn by Osvaldo Durana

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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

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Fuselage /Tail Boom Assembled Plans delivery.com Designed and drawn by Osvaldo Durana

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AILERONS PEDALS

RUDDER

MIXER

CONTROL SIDE STICK

ELEVATOR

CONTROL CABLES “TELEFLEX” TYPE TAIL GROUP

FIGHTER ULTRALIGHT

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

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2(.090”)

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

R15(.60”)

R13(.51”)

12,7(1/2”)

10(.40”)

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

30 (1.18”)

38(1.50”)

155 (6.10”)

*Dia22(.87”)

26(1.02”)

Pedal Tang 15(.60”)

R9(.35”)

Weld Dia. 5 (.187”)

5(.187”)

Aileron Control Link

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

6,35 (1/4”)

20(.79”)

33(1.30”)

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

Rod End Bearings Male thread

Tap tubes 1/4-28 thread or weld nut at both ends

32(1-1/4”)

5(.187”) 25,4(1”)

6(.24”)

5 (.187”)

20(.79”)

Bending lines 11(.43”)

12(.47”)

15(.60”)

85(3.35”)

8(.312”)

60(2.36”)

15(.60”)

Push-Pull Barr end Mat: Aluminum- 1 Required 36(1.42”)

Dia 12,7(1/2”)

20(.79”)

32(1.26”)

60(2.36”)

R10 (.40”)

130(5.19”)

Mat: Grilon 4 Reqd.

15(.60”)

12(.47”)

Pedal Bushing

2(.090”)

3,5(.137”)

Mat:Steel 1 Rqrd. 6,35(1/4”)

10(.39”)

36(1.42”)

60(2.36”)

25,4 (1”)

12,7(1/2”)

12,7 (1/2”)

Aileron mixer

R13(.51”)

36(1.42”) 45(1.77”)

50,8(2”) Dia 8 (.312”)

8 (.312”)

285(11.22”)

R 3 (.12”)

weld

Mat: Aluminum sheet 3(.125) thick. -2 Required 130(5-1\8”) 101(4”)

5(.187”)

R

Pedal

Dia12,7(.5”)

53(2.08”)

5(.187”)

**5(.187”)

Mat: Steel - 1 Reqd.

50(1.97”) 76(3”)

Control Arm

12,7(1/2”)

*Dia 22(.87”)

35(1.38”)

47(1.85”) 135(5.31”) 55(2.16”)

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

*Dia 22(.87”)

12,7(1/2”)

Control Stick end Mat: Aluminum- 1 Required

101 (4”) 140 (5.51”) 200 (7.87”)

FIGHTER ULTRALIGHT

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

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PEDALS

WING STRUTS Steel tube to connect “teleflex”

REAR SPAR Bushings

FRONT SPAR

Steel cable connect to fork

Wing strut fitting Strut inner link

Aluminum tubes

Spacers Wing strut tip

Wing Strut

Weld Wing strut are made from streamlined steel tube.

THROTTLE ASSY FIGHTER ULTRALIGHT

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

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ENGINE

Rubber mounts

Upper Bracket

Lower Bracket

Side Bracket

OS

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Boom

NA

External Adapter

Inner Adapter FIGHTER ULTRALIGHT

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Engine Mount Assembly Plans delivery.com Designed and drawn by Osvaldo Durana

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Side Bracket

Engine Mount Front View

1) 135º

Inner Adapter

Mat: Stainless Steel 3 (1/8”) Thick 2 Required

25,4 (1”)

Mat: Aluminum 2 required

164 (6.46”)

135º

135º

Boom

Bending Line

3)

60 (2.36”)

273 (10-3/4”)

1)

65 (2.56”)

Bending Line

R 10 (.39”)

65 (2.60”)

50,8 (2”) 50,8 (2”)

NOTE 1) Diameter according Rubber mounts

2) Diameter according engine bolts 3) Length according engine

25,4 (1”) 60 (2.36”)

R. 50,8 (2”)

65 (2.56”) 15 (.60”)

310 (12.20”)

25,4 (1”)

25.4 (1”)

R 10 (.39”)

25,4 (1”)

Dia 8 (5/16”)

External Adapter Mat: Aluminum 2 Required

Bending Line

25,4 (1”)

2)

50,8 (2”)

50.8 (2”)

Aluminum tube Dia. 101 (4”)

Bending Line

1)

60 (2.36”)

15 (.60”)

35(1.38”)

R 10 (.39”)

Upper Bracket

Dia 8 (5/16”)

Bending line Dia 8 (5/16”)

Mat: Stainless Steel 3 (1/8”) Thick 2 Required

According inner diameter of Boom

50,8 (2”)

65 (2.56”)

FIGHTER ULTRALIGHT

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Engine Mount Details Plans delivery.com Designed and drawn by Osvaldo Durana

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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

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

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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.

Don’t 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, 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 following drawing. Support Block

Hardwood pulley Diameter to fit tube

Harwood pulley

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

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

Page 5 shows the wing strut fittings bolted into the spar with two reinforcement bushing, which FIGHTER ULTRALIGHT In every assembly check the lengths of the bolts, are made from aluminum tubes. bushing) once tighten with a nut (self lockingPlans nuts)delivery.com only (Read Reinforcement Designed and drawn by Osvaldo Durana

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

Now with the Nicopress Tool, you can compress the nicopress sleeve (usually making three grooves along sleeve’s length), after that you can take away the cable clamp and the hose.

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

In the eye formed by the cable, put a thimble and adjust all the assembly, you can use a cable clamp to keep them in place. Thimble

To cut the cable, wrap it with electrical tape and cut it with chisel and hammer (never cut them with a welding torch, doing this could modify their mechanical properties)

This is a Nicopress sleeve that will be use to assemble the cables.

Cable clamp

Nicopress Tool

Now you can start making the wing ribs, according to the drawing in page 9, to make all ribs equal, cut a pattern from a 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 aileron spar from an aluminum tube diameter 38 (11/2”) mark the position of every aileron rib and drill a small hole through the spar, enlarge the hole in the inboard face of the spar to accept the aluminum rib (3/8” diameter tube) the trailing edge tube is fastened to the ribs with pop rivets. Once finished, place the aileron next to the wing in the right position, mark the position of each hinge, drill and bolt them in place.

num tubes that will support the boom (page 11) Rear boom support use an aluminum ring (page 12) to attach the boom (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 stainless steel brackets to connect the mast with the boom tube and the chassis. Reinforcement bushings When tubes are to be bolted, to avoid been flattened when the bolt union is tighten, you can insert a short piece of hardwood or Nylon turned to fit the inside diameter of the tube. In some instances the reinforcement can be achieved using small aluminum tube as bushing. e.g. for a 5/16” bolt (AN5) use as a bushing a 3/ 8” x .028 wall thickness tube for a 7/16” bolt (AN7) you can use a ½” x .028 wall thickness tube.

Wing Spar (page 5) Cockpit chassis Now you can start with the cockpit chassis, cutting and bending the side members, using the bending method previously explained (you will need to make another hardwood pulley to accept the 2” diameter tube) Cut the straight rear member and make all brackets and plates as explained in page 10 ;11 and 12. Fuselage nose plate (two are needed: upper and lower) make the upper first, fasten it to the side members as depicted in page 10 and using a cardboard as a template trace the lower plate which will be a little longer in order to accept the fork. (it 1) make the required holes through the spar could be convenient to have the fork already made) FIGHTER ULTRALIGHT (use a drill bit = bolt size) Once the chassis is made and all the parts bolted Plansalumidelivery.com Designed and drawn by Osvaldo Durana together you can cut and bend the 1-1/8”

Bushing Diameter holes

Bolt diameter holes

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

2) enlarge the holes (only on this face of the spar) to insert the reinforcement bushings, complete the assembly. Engine mount The drawing in page 19 and 20 are self explanatory, according to the engine selected you will have to vary the position of some holes (our prototype used a Rotax engine) The design of this mount allows it to slide over the boom tube, 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 equipment or the knowledge to do the welding find a welding shop in your area and get your gear welded. The EAA have several good books about welding that can guide you through this process. Page 14 shows the wheel and brake assembly,

This is just a general guideline to help you to tackle this project, more information about specifically subjects like welding, covering or working with composites/fiberglass can be find at your local library . Abundant material and help can be found at the Experimental Aircraft Association (www.eaa.org)

Updated Mar-20-2001

Control system This aircraft employ a flexible push-pull control system often called “Teleflex” which simplified the task and 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 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

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Designed and drawn by Osvaldo Durana