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Airplane's

For anyone interested in flying, here is a very economical way to do so.

The Ultralight flier envies the Cessna flier.
The Cessna flier envies the twin engine Beechcraft flier and etc. all the way to the jumbo jet pilot...
Whoever sees the Ultralight pilot and envies him thinks.......
"Now that's flying"

Airplane
This is the second Ultralight that I built and sold.

Scratch building yourself an airplane is an exciting and rewarding project, especially when the time comes to take that first flight! There's just nothing like taking off for the first time, climbing above the fields and trees, in a plane that you crafted with your own hands. The time spent pouring over the plans and fashioning the many parts, seems a small price to pay for such a thrill!

 

Tiger Cub Ultralight

Airplane


The Tiger Cub UL can be scratch built from plans making it very economical to build!
The airframe is built of aluminum tubing with aluminum gussets and brackets at the joints, fastened together with bolts and rivets.
Johnston Aviation can provide you with a very detailed set of plans that will guide you, step by step through the process, in a logical and progressive order, from ordering the materials ( down to the last bolt and washer), to going through the preflight check list, in preparation for your first flight!
A technical assistance line is maintained to answer any questions that may come up during construction.

The plans include a complete materials and vender list.
The material list gives a list of the sizes and amounts of all the aluminum and chrome molly tube and sheet needed to build the airframe, a list of all the An hardware sizes and quantities needed and a list of all the rest of the materials needed to complete the airplane, with descriptions and venders part numbers for hard to find or describe parts.
The vender list is a listing of all the venders that we buy materials from and what materials they carry.
All the materials needed to build a Tiger Cub UL (less engine prop and instruments) can be purchased from these venders for under $4500.00 as of 1/07.

The plans have full size prints of all the gussets
The gusset prints are organized by thickness from .025 to .125 the patterns can be cut out and traced onto the aluminum sheet with a fine tipped marker. No scaling from the plans required! directions and tips for cutting out the gussets are included in part one of the assembly manual.

Full size prints, of the chromemoly and machined parts, are included.
If you don't weld or have access to machines these prints can be taken to a local fabricating shop or machine shop, or they can be purchased ready made from Johnston Aviation.
¼ scale prints (19" by 30" prints) of the wings, tail surfaces, fuselage and bulkhead panels. The panel prints have all the measurements needed to lay out the part on your work table, so you don't have to scale your measurements from the prints, eliminating a common source of errors.

The plans also include an assembly manual (over 200 - 11" by 17" ) pages of pictures and text), that gives step by step directions and tips to guide you through assembly, rigging, covering, wiring, plumbing and finishing.

Available since Jan. of 2000, over 300 sets of plans have been shipped (as of 1/2007) and Tiger Cub UL's are going together all over the world.

Est. build time for scratch built...650 hrs.
Price for a complete set of plans $250.00, Too order send check or money order to,

Johnston Aviation
407 Morganza rd.
Canonsburg, Pa. 15317
724 745 4040

To make the building process faster Johnston Aviation also offers:
Parts packages

Visit the Tiger Cub website for more great offers from Johnston Aviation including a two place Airplane.

Click here for Plans, Kits or complete Airplanes. Tiger Cub Ultralight Airplane  

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wind My Tiger Cub
I begin building my Tiger cub in May 2007
 
Hold mouse over to read caption.

Click to enlarge and open a new window

This is my first Tiger cub part, The tail section The elevators Flapperon mixer control Fuselage tail section Cabin section Joining the tail to the Cabin section

Cross sections in place Diagonal brace in the flapperon mixer control arm Diagonal brace in the flapperon mixer control arm 4130 steel tube in tail section Wing frame Squaring the ribs  

Last rib being squared Jury strut bracket Setting up to install the struts Tail section done Diagonal braces for the cabin hoops Pressurized fuel tank

A view under the instrument panel Inside door latch Outside door latch  Where all my money is at Cowling installed Bottom hinge

  Ready to cover covered Half covered Velcro gap seal installed Rudder section with gap seal installed Wing on my home made rotisserie

 Bottom covered Riveting  Covered Velcro Gap seal installed Painted wing Painted Airplane

Fuselage Gap seal Streamline Jury strut Streamline Jury strut clecoed on  Fuselage Gap seal sealed with Stewart systems glue 6 inch by 1 1/4 pneumatic tail wheel Initial engine warm-up

5000 + rivets later

  Waiting for the wind to stop blowing

My first taxi run and flight, September 20 2008 My first flight in my Tiger Cub, September 20 2008 My first taxi run and flight, September 20 2008 

Click here for the first flight
images2/VID00004.AVI

Flying Tiger Cub

Upgrades and modifications to my Tiger Cub from factory specs are as follows

1- Chrome molly 4130 tail post and in the lower section of the rudder

2- Larger 5/16" diameter tubing on the trailing edge of the tail section and flapperon's

3- Diagonal bracing on the flapperon control arm

4- 7/8” 0.58 insert inside the flapperon control arm cross shaft.

5- Added a 1” 0.58 tube between the rear landing U brackets with a 1” X 4” 0.58 plate on each side and longer bolts to accommodate (3 rivets per plate)

6- Felt on leading edge of each wing with nine 1/2” dia. tube ribs per wing, 1.7 oz. cloth riveted every 6” top and bottom, Velcro gap seal glued on, 5 inspection rings and 2 drain grommets per wing.

7-  Cross braces on the over head cabin bows to the front header tube. From where the rear of the windshield attaches.  

8- Streamlined struts and jury struts (Chrome molly 4130 jury struts brackets were installed in each wing after the bottom cloth was attached and shrunk)

9- Galvanized firewall with high temp foam rubber sound barrier glued on inside cockpit.

10- Avid disc brakes with heal pedals

11- 800 x 6 tundra tires on 6” Azusa aluminum rims machined for 3/4"X 1- 5/8” precision seal bearings

12- Cotter pin installed in stub end of axles as a safety precaution of loose locking collar

13- Chrome molly 4130 streamlined Landing gear cross brace.

14- Fan cooled Rotax 503 with single Bing 54/36 carburetor, Dual Ducati ignition, BR8EIX spark plugs (with holes drilled into cooling shroud to install ties around wire ends to prevent plug wires from falling off), provision 8 - 2.58 to 1 B gear box, EGT threaded exhaust manifold, standard muffler with silencer, 62” ground adjustable GSC tech 2 prop with leading edge tape, 8” scull cap prop spinner and a Rotax electric starter.

15- Instrument panel is mounted on 6 rubber standoffs with the following instruments installed - EGT, CHT, Tachometer, Vertical speed indicator, Air speed indicator, Bank and slip indicator, Fuel pressure gauge, Vertical card compass, Vacuum gauge, Attitude Gyro (with regulator, filter and exterior mounted Ventura),
Vanier throttle control, plunger fuel primmer, electric fuel pump in series with Mikuni fuel pump, fuel filter and shutoff valve, 5 gallon fuel tank, voltage regulator, keyed ignition magneto test switch,  push button Starter switch, Potter Brumfield aircraft circuit breakers on all electrical circuits and pull to unlock aircraft type electrical toggle switches.

16- 2 hinges in the lower engine cover (1 on each side of the exhaust silencer)

17- Spring loaded Door latch (operational both inside and outside)

18- both right and left windows that will be able to open with spring loaded latches or can be removed. 

19- Pressurized fuel tank vent tube.

20-  6" x 1.25" pneumatic tail wheel.

October 2008
21- After my first test flight and having done the weight and balance I have decided to move my engine back as close as possible to the firewall so as not to have so much added weight in the tail.
I have moved it back 2 3/4 inches with a 1 1/2" muffler clearance to the firewall and added a fiberglass heat shield to the firewall.
I will installed Muffler wrap to the muffler and exhaust system.
My new engine cover will have a row of louvers installed for the engine fan outlet hole.
I will take more pictures latter.

I found the covering process to be the simplest thing to do on my Tiger cub after watching the DVD’s from http://www.stewartsystems.aero/
 I bought all my covering products from them at a very good price. And used it all without any special breathing apparatus right in my living room.
They do not have their DVD’s on the web site yet but you can get them by calling #1-888-EKO-POLY  

One construction tip to center drill your small tubing is to use a 3 or 4” long piece of 1/8"x1/2"x1/2” angle with a 1/8” hole drilled in the V 1/8” from the end. Then turn it over and place it on your tubing to use as a drill guide. It will stop the drill from walking off the tube center. 
 
airplane

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My Wife's SMART toy

We get 38 to 42 miles per gallon!
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Quotes I live by

Never argue with an idiot. He'll drag you down to his level and beat you with experience.

 Either, Lead - Follow; or get the hell out of my way.

Being on the tightrope is living; Everything else is waiting.

Always do right. This will gratify some and astonish the rest.

Being an egotistical a--hole, I DO IT MY WAY (after I get my wife's permission).
(Written by Wayne Pederson. If it fits, you can quote me)  

No bird soars too high if he soars with his own wings.

MAY GOD BLESS YOU AND YOURS

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