How to Build Your Own Ultra Light Aircraft

Written by eric cedric
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How to Build Your Own Ultra Light Aircraft
Ultralight aircraft are small and are not under the same FAA scrutiny as other aircraft. (ultralight in the sky image by Ivonne Wierink from

Ultralight aircraft are extremely light weight and are designed to fly shorter distances at lower altitudes. Ultralights, when built, are not required to comply with FAA air worthiness rules or certifications. Plan to build an ultralight over the course of a few weeks or months. Be sure to have a suitably large work space that is ventilated as the glues used may be noxious. Aircraft and aviation requires diligence, training and precision.

Skill level:

Things you need

  • Power tools
  • Large enclosed work area, ventilated
  • Ultralight aircraft kit
  • DVD player
  • Engine crane

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  1. 1

    Read the ultralight kit's instruction manual and watch the kit's DVD. Read these several times and watch the DVD enough to understand the process. Break down the ultralight assembly into three sections: engine, airframe and wings.

  2. 2

    Set out the airframe pieces from the kit in the hangar to begin the project. Assemble the airframe first according to the kit's instructions.

  3. 3

    Build or bring in the ultralight engine. Hang the engine on the mounting crane and test the engine prior to installation on the airframe. Once built and tested, keep the engine on the mount until ready to attach to the airframe.

  4. 4

    Assemble the wings as per the kit's instructions. When using any epoxy or glue, should your kit use a fabric-on-frame style wing, be sure to ventilate the hanger or work space. Use a mask and safety gloves.

  5. 5

    Set the engine into the airframe and then attach the wings to the aircraft. Assemble the landing gear and mount the tires to the craft.

  6. 6

    Test all connections numerous times. Safety redundancies prevent accidents and injuries.

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