Aero Sport 103 & Aero Sport Ultra

Aero Sport 103

Aero Sport Ultra

While the names Aero Sport 103 and Aero Sport Ultra are new, the designs have a very long and well documented history.  Both aircraft are new in name only and have a legacy that extends as far back as the Freebird II which was introduced to the world at Sun & Fun in 1996 by Freebird Airplane Company of Marshville, NC.  The complete history of these designs has been documented in the construction manual as well as the summary of aircraft built under the ownership of the previous companies who supported the designs over the years.

The Aero Sport 103 is a single seat design which falls under the Federal Aviation Regulation (FAR) Part 103 in the United States and qualifies as an ultralight.  This ultralight is constructed from plans using bolted aluminum tubing and features standard three axis controls.  The overall structure is built mainly of 6061 T-6 aluminum and the fuselage, wings and control surfaces are covered with aircraft fabric.  The fabric covering can be a double surface Dacron sailcloth sleeve or a lightweight polyester fabric such as the Poly-Fiber process.  The wing can be flown successfully with a single surface, but a double surface polyester covering is recommended.  The prototype was tested and flown with a Rotax 447 and had a standard empty weight of 254 lbs. (113 kg).  The acceptable horsepower range for the Aero Sport 103 is 22 hp to 52 hp (16 kW to 39 kW).  To date, there have been a total of 357 aircraft built.

Features

  • Fits in Garage
  • Detachable Wings (15 minutes)
  • Anodized Aluminum Construction
  • 3 Axis Control System
  • Double or Single Surface Dacron Sails or Stits Poly-Fiber
  • Strut Braced Wings (no wires)
  • Steerable Nose Wheel
  • FAA Part 103 Legal - No Pilots License Required
  • Large Instrument Panel
  • Standard Aircraft Components
  • Rubber Mounted Landing Gear
  • Adaptable to Floats
  • Hydraulic or Mechanical Brakes – Optional (may not meet Part 103)
  • Fiberglass Seat w/Optional Seat Cover
  • Full or Partial Windshield
  • Fiberglass Nosecone Fairing (or wind in your face open flying)

Specifications

  • Empty Weight:                                      254 lbs.
  • Gross Weight:                                       530 lbs.
  • Wingspan:                                             26’ 6”
  • Wing Area:                                            121 sq. ft.
  • Length:                                                 16’ 7”
  • Height:                                                  6’ 8”
  • Build Time from Plans:                         250 - 300 hours
  • Fuel Tank:                                             5 US Gallons
  • Cruise Range:                                      25/60 MPH
  • Maximum Prop Length:                        72”
  • Slow Stall Speed:                                 24 MPH

 Performance
  • Engine used on prototype:                   *447 Rotax
  • Power:                                                  40 HP (22 hp to 52 hp)
  • Cruise Speed                                       55 MPH
  • Top Speed:                                           63 MPH
  • Stall Speed:                                          22 MPH
  • VNE:                                                     75 MPH
  • Rate of Climb:                                      850 FPM
  • Take off Distance:                                75 ft.

*It is difficult to maintain Part 103 weight using the Rotax 447 engine, however, this has been accomplished by the previous design owners.  There are recommendations for lightening the airframe documented in the plans, these should be used to help keep weight down.  For weight savings and great performance, the Kawaski 340 and 440-A engines would be a good choice for this design.  The newer "Paraglider" type engines such as the Polini Thor as well as MZ and Hirth engines will help keep weight down as well.  The builder must remember that this design is an ultralight, any added weight will deter performance and cause the design to not qualify for Part 103.  Of course, the Aero Sport 103 may also be registered in the Experimental Amateur Built Category in the USA and obtain an airworthiness certification and N-Number. 

The Aero Sport Ultra is a 2-seat tandem designed aircraft which falls under the FAA Experimental Amateur Built category in the USA. This aircraft is constructed from the same set of plans that are used to build the Aero Sport 103.  There are additional drawings and notes that document the changes which are required to convert the single place into a 2-seater.  The construction method is of bolted aluminum tubing and features standard three axis controls.  Like the Aero Sport 103, the overall structure is made mainly of 6061 T-6 aluminum and the rear fuselage, wings and control surfaces are covered with aircraft fabric.  The fabric covering can be a single surface or double surface Dacron sailcloth sleeve or a lightweight polyester fabric such as the Poly-Fiber process.  The wing can be flown successfully with a single surface, but a double surface polyester covering is recommended.  The prototype was tested and flown with a Rotax 503 and had a standard empty weight of 295 lbs. (113 kg).  The acceptable power range for the Aero Sport Ultra is 40 to 65 hp (29.83 to 48.5 kW).  To date, there have been a total of 352 aircraft built.

Features

  • Fits in Garage
  • Tandem Seating
  • Anodized Aluminum Construction
  • Strut Braced Wings (no wires)
  • 3 Axis Control System
  • Double Surface Dacron Sails or “Stits” Poly-Fiber
  • Detachable Wings (15 minutes)
  • Fiberglass Seats
  • Seat Covers
  • Steerable Nose Wheel
  • Slow Stall Speed 32 MPH
  • Adaptable to Floats
  • Cruise Range 32/75 MPH
  • Maximum Prop Length 72”
  • Full or Partial Windshield
  • Standard Aircraft Components
  • Large Instrument Panel
  • Top Mounted Engine
  • Power Range 40/65 HP
  • Rubber Mounted Landing Gear
  • Full or Partial Windshield
  • Fiberglass Nosecone Fairing (or wind in your face open flying)
Specifications
  • Empty Weight:                                     295 lbs.
  • Gross Weight:                                      900 lbs.
  • Wingspan:                                            26’ 6”
  • Wing Area:                                           121 sq. ft.
  • Length:                                                 17’ 1”
  • Height:                                                  6’ 8”
  • Fuel Capacity:                                      8.5 Gallons
  • Build Time Plans:                                 250 hours
Performance
  • Engine Used for Test:                          Rotax 503
  • Power:                                                 50 HP
  • Cruise Speed:                                     75 MPH
  • Top Speed:                                          80 MPH
  • Stall Speed:                                        32 MPH
  • VNE Speed:                                        95 MPH
  • Rate of Climb:                                     800 FPM

Stits Poly-fiber or pre-sewn Dacron sails have been used on both designs to provide the required covering.  Great Salt Lake Sails out of Kaysville, UT developed and produced the sails for the predecessor to the Aero Sport 103 and Aero Sport Ultra designs. We do not know at this time if they will provide the sails or if they still have the patterns.  Other manufactures such as Ultralight Sails Canada or Great Sails of Midland, Michigan may be able to provide sails for your project if this is the covering material you prefer.  We do not provide Dacron sails and recommend the Stits Poly-Fiber method to cover the designs.

The plans consist of:

  • A 70-page, spiral bound construction manual printed on 8 1/2" x 11" paper
  • A 146 page, extremely detailed CAD drawn, spiral bound drawing set on 8 1/2" x 11" paper
  • Two 1:1 templates printed full size:
  •      Aero Sport 103 & Ultra Template 1 - 36" x 66.15" - Bending Jig Template
  •      Aero Sport 103 & Ultra Template 2 - 36" x 151.84" - Bending Jig template and build pattern

The plans are fully detailed engineered CAD drawings for both designs.  Each drawing has detailed dimensions and lists the material required to build the part, and they are clearly drawn.  This is a perfect package for anyone who wants to build their own Ultralight from scratch.  The construction manual details every part and includes an in-depth Bill of Materials (BOM), and a "Cut Sheet" which identifies the best way to purchase the building material to save the homebuilder's money.  The templates provide a 1:1 print out size for each part that requires bending.  It also provides the layout of the bending fixture that you will need to make in order to produce the required bends in the aluminum tubes.  

This style of construction is easy to perform, and the homebuilder will find this to be an extremely rewarding and educational experience. If you have issues, don't worry!  We're here to answer any questions you have as you go.  If you find that a particular part is too difficult to make or bend, you can have a muffler or machine shop make the bends for you.  The big box airplane stores are also available so you can purchase the off the shelf items.  We have included a supplier resource list in the construction manual that will show you who you can reach out to purchase parts.

The Aero Sport 103 & Aero Sport Ultra plans may be purchased for $200.00 USD per set plus shipping cost.

Shipping Cost

U.S.P.S. Mail to Continental US:          $21.65 Ground (4 - 5 days) or $31.15 Priority (2 - 3 days) 
U.S.P.S. Mail to Alaska, Hawaii:           Please contact us for shipping cost
U.S.P.S. Mail to Canada:                      $56.56 International Rate (6 - 10 days)
U.S.P.S. Mail to other countries:           Please contact us for shipping costs

The plan sets will be shipped out insured and placed in a padded shipping envelope for protection. You may use a personal check (must clear both banks), US Postal Money Order, Certified Check, or Cashier's Check for payment purposes. Note: Georgia residents must add 7% sales tax.

If you wish to purchase online, please use PayPal as your option, this will allow you to use:

Click on the PayPal image below to go to the PayPal website. Use "contact @ adamsaero dot com" for the recipient ("To") e-mail address. Remember to add the appropriate shipping amount plus tax if applicable to the plans total.  Please e-mail "kenneth.l.adams.jr @ gmail dot com" or call 404.219.7326 when you use PayPal, we have had issues with their notification process.

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                                                               This information is subject to change without notice.