Fighter Ultralight Plans

OSVALDO DURANA
OS
VA
UR
OD
LD
AN
FIGHTER ULTRALIGHT
Three view
Plans delivery.com Designed and drawn by Osvaldo Durana
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
VA
LD
DU
RA
NA
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
Tail Group assembly

RUDDER .
SHORT BUSHING
Dia. 6,35 (.25)
Inner Bushing (short)

203
(8)
406
(16)
12
(.47)
22 (.86)
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
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)
127
(5)
Rad. 9 (.35)
450
(17-3/4)
FIGHTER ULTRALIGHT
Tail Group /Rudder

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
Dia. 19 (3/4) x 1,65 (.065)
Rad. 152 (6)
Dia. 25,4 (1) x 1,65 (.065)
203 (8)
2500 (98.425)
Lower link attachment point

(see plan #2)
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. 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
Tail Group /Elevator

WING
A
Wing Spar
Wing Tip
Wing Spar Bracket
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
Reinforcement Bushings
Link
OS
Bolts
VA
LD
DU
RA
NA
Wing strut fittings
Turnbuckles
Tensor Cable
Rear Spar
Wing Root
Front Spar
Wing Spar
FIGHTER ULTRALIGHT
Wing /Assembly
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
Wing /Details
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
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 .
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
Wing /Construction Details

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
108
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)
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)
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
Wing /Construction Details

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
Wing /Airfoil-Wing rib

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
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
Fuselage/Cockpit - Assembly Details

10
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)

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
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
Boom / Fuselage components

11
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

5 (.190) Thick
4 Required
Landing Gear Bracket
Dia 8
(.312)
!4(.55)

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 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)
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)
Fuselage brackets
12
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
Landing Gear
13
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
Actuator arm
SV
AL
AN
Self locking nuts
Slot for positioning lug
Brake plate rear view
FIGHTER ULTRALIGHT
Rear Wheel Assembly / Axle

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
D
AL
DU
RA
NA
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
Fuselage /Tail Boom Assembled

15
AILERONS
PEDALS
RUDDER
MIXER
CONTROL SIDE STICK
ELEVATOR
CONTROL CABLES
TELEFLEX TYPE
TAIL GROUP
FIGHTER ULTRALIGHT
Control System
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)
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)
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
Control components
17
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
Wing Struts / Pedals Assembly

18
ENGINE
Rubber mounts
Upper Bracket
Lower Bracket
Side Bracket
OS
D
AL
DU
RA
Boom
NA
External Adapter
Inner Adapter
FIGHTER ULTRALIGHT
Engine Mount Assembly

19
Side Bracket
Engine Mount
Front View
1)
135
Inner Adapter

3 (1/8) Thick
2 Required
25,4
(1)
Mat: Aluminum 2 required
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
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)

3 (1/8) Thick
2 Required
According inner
diameter of
Boom
50,8 (2)
65
(2.56)
FIGHTER ULTRALIGHT
Engine Mount Details

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
Cockpit Enclosure Three view

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
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, 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 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 dont 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 dont
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.
Its 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 sleeves 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 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 (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 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 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, 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
TIG /MIG process, if you dont 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 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
Designed and drawn by Osvaldo Durana

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Fighter Ultralight Plans

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OSVALDO DURANA

Long Inner Bushing

Strut Upper Link

Dia. 25,4 (1)

Tail group Strut

(to fit tube)

Tail Group assembly

Dia. 6,35 (.25)

Inner Bushing (short)

Tap for AN4

Tap for AN4

Dia. To fit snuggly

Radius 127 (5)

Rad. 127 (5)

Tail Group /Rudder

Lower link attachment point

Dia. 19 (3/4) x 1,65 (.065)

Rad. 152 (6)

Dia. 25,4 (1) x 1,65 (.065)

Lower link attachment point

Dia. 6,35 (.25)

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

TAIL GROUP STRUTS .

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

Stainless Steel 1,5 (.063)

* Once the tail group is built and assembled, align it and

Tail Group /Elevator

Wing Spar Bracket

Wing rib Detail

Wing strut fittings

Aileron Ribs Aluminum tube Dia. 9,5

Aluminum Sheet tip

Steel pop rivet

Aileron Tip Assembly

5 Steel pop rivets

Hardwood inner reinforcement

Aileron Control Arm

Wing tip bolted

Wing ribs (9 per wing)

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

6061-T6 Aluminum Tube Dia

Wing /Construction Details

AILERON CONTROL ARM

Dia. 6,35 (.25)

Bend around Dia 8 (.312)

STRUT INNER LINK

Mat: Stainless Steel

Dia. 6,36 (.25)

WING STRUT FITTING

WING STRUT TIP

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

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

Material :Stainless Steel

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

Wing /Construction Details

Mat: 2024-T3 Aluminum Sheet

Drill for pop rivets

Wing Rib Attachment

Detail rear spar

Wing /Airfoil-Wing rib

Fuselage nose plate

Central boom support

1) Boom support bracket

Fuselage/Cockpit - Assembly Details