Web site www.poorboyaviation.com      E-mail  hartungj@srt.com


       April 2011                                      Pg-1


These plans are for the PB-1 only, please ignore other references.

Goals of the PoorBoy designs are straight forward construction, and low cost. 


  Handling qualities of the Poorboy are intermediate Ultralight Aircraft.   

Entry level handling Ultralight planes will fly hands off easily when trimmed

properly and are very stable usually with long wings and generous dihedral.  

Intermediate handling Ultralight planes (like the Poorboy) usually have shorter

wings with less dihedral and require more attention to the controls.  Advanced

handling Ultralight planes require constant control input to keep the plane

responding to the pilots wishes and will respond quickly to the controls as

acrobatic maneuvers would require (short wings and center of gravity centered

about the mid point of the airplanes mass). 



The PB-1 is designed around the rotax 503 DC/DI, standard model, a second PB-1

is flying well using a 35hp cuyuna, use 35 to 50 hp air cooled engines). 

The PB-H is a heavier version of the PB-1 designed for heavy pilots still using

a 503 Dual carb.



  Wingspan 25’~27’ (depends on wing tip)

  Wing Area  125 sq/ft.              --  Wing Cord 5’         

  Length 20’, Width 25’, Height 6’    --  Never exceed speed 75 mph. 

  Build time 450 hrs.                --  Engine Rotax 503 air cooled. 


  Construction Method: 

Aluminum tube is the primary building material in the PoorBoy and the reason

for that choice is based on quick building times, ease of repair

techniques, and the ability to see problems during safety inspections as

compared to Wood or composites.  The Poorboy use 4130 steel parts in

critical areas and the covering is heat shrink Dacron fabric. 

  Tools required are what most folks have in their homes, you will also need

additional tools such as cable swage tool, pipe bender, and pop rivet

gun.  Steel parts can be supplied by us when requested, you can build the steel

parts yourself from the plans if you have the welder also a small hydraulic press. 



  Materials list include 6061 T-6 aluminum, 4130 steel for some parts, fabric

covering w/supplies, and the engine.  A few general hardware items like

wheels/tires are used.  Aircraft grade hardware is required for all bolts,

turnbuckles, etc.  Cost to build should run about $ 3000. for materials to

build the airframe.  Covering cloth and cement cost about $300.00 to $500.00.

Latex paint option can save on painting costs (about $200). 


     April 2011                                                     Pg-2


  Materials are available from suppliers like Wicks (1 800 221-9425) and

Aircraft Spruce & Specialty (1 800 824-1930). 

We use a Rotax 503 engine on the PB-1, others like Kawasaki, Hirth, Cuyuna (2SI)

can work well, power differences are obviously going to effect flight performance. 

I have a PB-1 flying with a Cuyuna UL202 35hp that does fine so the 503 is not

the only engine possibility.


Building has some benefits, you can buy some parts and build as your budget allows

and you get the enjoyment and education of the project.  Building also means you

know what you have internally and you have a new plane.


  This is our not responsible for your butt statement. (liability release).

Safety is the big concern.  Flying Ultralight aircraft can be a risky activity,

a person needs to be acutely aware of the dangers to life and limb.  PoorBoy

Aviation takes no responsibility for your safety in this endeavor, these plans

are available with that understanding.  These plans will show you how to build

Poorboy aircraft based on the flying prototype that PoorBoy Aviation flies.   

If you do not have experience to evaluate building and flying an Ultralight

you should take the information and plans to someone with sufficient knowledge

that you trust to help you with an evaluation of this activity. 


  * If you are new to Ultralight aircraft:         

  Risk Management: The first year of driving a car or motorcycle is

statistically the most dangerous, this would also be true of Ultralights.

Riding a motorcycle might be considered twice as risky as driving a

car, flying an Ultralight is risky similar to riding a motorcycle. 

There is a learning curve associated with each of these activities.  Flying

Ultralights is not difficult “however” the knowledge associated with it is



  * TRAINING  What to expect: You should expect about 5 to 7 hrs of instruction

time in a general aviation trainer or ultralight trainer close to the point of

“solo”.  What your intension would be is to learn the basic reactions and skills

of flying, this is the minimum hours of training a person needs and is not a license

requirement like the Sport Pilot License but is what is needed to be able to fly

an Ultralight with some margin of safety.  You will need to know the rules of the

airways etc. "pilot training".  People vary in training needs, the shortest and

quickest people to be trained are not necessarily the safest pilot.


  * Special Note: As an Ultralight Pilot you have the additional duties of

engine and airframe mechanic, this is not like flying a certified aircraft where

someone else checks to make sure the aircraft is safe to fly.  As an Ultralight

Pilot you are the ultimate authority and must decide if the design and condition

of the aircraft are adequate for safe flight.  You can gain further maintenance

information by contacting ultralight flight instructors, airframe mechanics and

other ultra-lighters that you have confidence in, an excellent source is EAA

ultralight chapters, EAA national and ASC (Aero Sports Connection).  Try your

local FBO also.  If you are going the Sport Pilot route and N number the aircraft

these issues are covered in that training. 


      April 2011                                          Pg-3                     

“The MOPED of aviation”

  An Ultralight aircraft: --  is defined as a single occupant, 254 lb. aircraft,

carrying 5 gal. of fuel, stall speed not to exceed 24 knots (28mph), not to

exceed cruise speed of 55 knots (63mph).   A Ultralight can weight as much as 278

lbs. with a ballistic chute (24 lbs. weight allowance).   Aircraft meeting these

parameters do not require a pilots license.  The Spirit of Part 103 rule allows

for single occupant flight of an aircraft without a license with low speeds and

light weight = low kinetic energy.  This formula lowers the danger to the pilot,

property, and the public; as an aircraft adds weight & speed the kinetic energy

goes up, greater fuel capacity increases fire danger and so forth.  Fat Ultralights

have come about mostly from a desire to increase airframe strength, then followed

a desire for heavier engines (safer performance), greater fuel capacity (it isn’t

a good idea to run out of gas) and so forth.  You don’t want to get too far from the

“spirit” of the law, the FAA has been somewhat tolerant of Fat Ultralights but as

the definition is stretched their tolerance may decrease.  The alternative to flying

as an Ultralight is to get a Sport Pilots license and “N” number the plane. 

Ultralights often require state registration, also knowledge by the pilot of aircraft

rules and regulations, and of course the knowledge and skill of pilot in command.

The exception should not be made to fly a two place Ultralight without registration,

proper training and (license), the FAA will not be tolerant of this, nor in good

judgment should you.


  The PoorBoy has good handling and performance; it has a nice design look and the

fit and finish is up to you.  The Poorboy is designed for those people who want to

do the building themselves and do it inexpensively. 



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