[UPDATE spring 2014] — The Aerolite 103 is now manufacturered in Deland, Florida by U-Fly-It, the contact info for which is located at the end of this article. In addition, a new company is representing the product in Europe under the name Vierwerk. The design appears to be enjoying great interest and support at this time. [UPDATE summer 2011] — Aero-Works, the company referred to in this article written in 1997, left the business several years ago. During its absence a different producer, Wings of Freedom, offered their Phoenix-103, a derivation of the Aero-Lite 103 but with numerous small changes. This article refers to the aircraft built by AeroWorks and will not be identical to the Aero-Lite 103. The companies are different and Terry Raber has no association with Wings of Freedom. Now, in the summer of 2011, I am happy to report the original designer is again the producer of the Aerolite 103, and it retains an excellent price, less than $15,000.
Aero-lite 103
Seating | Single-seater |
Empty weight | 250 pounds |
Gross weight | 520 pounds |
Wingspan | 26 feet 10 inches |
Wing area | 124 square feet |
Length | 17 feet |
Load Limit | +4 Gs, -2.8 Gs |
Fuel Capacity | 5 gallons |
Standard engine | 2si 460F-35 |
Power | 35 hp at 6,000 rpm |
Power loading | 14.9 lbs/horsepower |
Max Speed | 63 mph |
Cruise speed | 55 mph |
Stall Speed (Flaps) | 28 mph |
Stall Speed | 30 mph |
Never exceed speed | 75 mph |
Rate of climb at gross | 500 feet/minute |
Takeoff distance at gross | 100-200 feet |
Landing distance at gross | 100-200 feet |
Standard Features | Tricycle gear, 2si 460F-35 engine with belt reduction drive, yoke and rudder pedals 3-axis control, steerable nosewheel, twist grip throttle, nondifferential mechanical drum brakes, flaps, removable strut-braced wings, pilot fairing and windshield, instruments (altimeter, airspeed, tach, EGT, CHT, slip/skid indicator), 3-blade nylon prop, 4-point pilot restraint, 6-inch aluminum wheels, landing gear leg flex suspension, all covering materials (including paint) included. |
Options | Ballistic parachute, factory-assembled option. |
Construction | Aluminum tubing airframe, 4130 chromoly steel, dope and fabric covering. |
Design
Cosmetic appearance, structural integrity, achievement of design goals, effectiveness of aerodynamics, ergonomics.
Pros - Refreshing new strutted design, incorporating the best of several popular ultralights. Meets Part 103 weight (less than 254 pounds empty weight) even with a marvelous load of standard equipment. Conventional tri-gear configuration is preferred by most pilots. Debut model was one of the best first efforts I've seen, especially for a new company.
Cons - Company is too new at manufacturing to judge on some matters (though proprietor Terry Raber has been in the ultralight industry for quite a while). Sixty percent of the market buys 2-seaters, and no 2-seat Aero-Lite offered yet.
Systems
Subsystems available to pilot such as: Flaps; Fuel sources; Electric start; In-air restart; Brakes; Engine controls; Navigations; Radio; (items covered may be optional).
Pros - Surprising number of standard systems for a Part 103 ultralight: flaps, brakes, 3-blade nylon prop, 4-point pilot restraint harness, etc. Flaps are infinitely adjustable through a hand crank; available to 40° down. Fuel quantity indicator aft of the seat can be seen with a twist in the seat (tube down side of tank). Fueling should be spill-free inside. Pull starter reasonably accessible from seat.
Cons - Hand-cranked flaps don't deploy or retract as quickly as lever-controlled surfaces. Though an engine isn't a "system," some will criticize aspects of it: for example, the belt drive system from 2si. Brakes are nondifferential.
Cockpit/Cabin
Instrumentation; Ergonomics of controls; Creature comforts; (items covered may be optional).
Pros - Not only is the seat comfortable, the surroundings are big enough for large pilots (up to about 235 pounds, which covers the vast majority). A 4-point pilot restraint system is appreciated. Open cabin gives ultralight feeling, yet the pilot is protected from windblast.
Cons - Too "airy" for cold climates, but Raber promises a full enclosure next year (though this may not be available under Part 103 weight). Entry around a few tubes may be a bit challenging for disadvantaged pilots. Reach to panel is beyond most pilots' arms. Space for radio is minimal.
Ground Handling
Taxi visibility; Steering; Turn radius; Shock absorption; Stance/Stability; Braking.
Pros - Precise steering combined with brakes make for simple ground handling. Brakes were surprisingly effective. Turn diameter was quite good. Several inches of ground clearance will help on rougher fields. A small tailwheel keeps the rudder from scraping if you bounce back to the rear. Six-inch aluminum wheels give secure contact.
Cons - Upward visibility makes checking for traffic a little tougher. Sits on tail when not occupied (like many ultralights). No easy seat adjustment. Shock absorption is limited to landing gear leg flex and air in the tires.
Takeoff/Landing
Qualities; Efficiency; Ease; Comparative values.
Pros - Wonderful controls for crosswind conditions. Adequate power for energized takeoff rolls. Wide main gear stance sure to help in some situations. Typical takeoff is about 40 mph and approaches are 40-50, an adequately slow range for a Part 103 ultralight. Initial climbout is steep and fast. Short ground roll on both takeoff and landing.
Cons - Slips won't be a useful landing feature due to the lack of side area (though the highly drooped flaps make up for this shortcoming). It's an ultralight; dissipates energy quickly, so you'll want to retain a little extra speed.
Control
Quality and quantity for: Coordination; Authority; Pressures; Response; and Coupling.
Pros - Yeah! Love the controls. So will you. Fast, light and predictable - Raber has done his design work well. Roll isn't twitchy, yet offers about 2.5 seconds 45° to 45° bank (quite fast). Precision turns were easily done and very enjoyable. Harmony between controls assures you can do quality Dutch rolls quickly and to steeper angles.
Cons - About all I might complain about is the lack of slower flap response due to a crank input. Ran a little low on backstick range in steep turns (commonly cured with 100 extra rpm). I didn't care for the twist grip of the throttle.
Performance
Climb; Glide; Sink; Cruise/stall/max speeds; Endurance; Range; Maneuverability.
Pros - The Aero-Lite 103 does well on 35 horses from the 2si 460F-35 powerplant. Sink rate is low, benefiting from the ultralight's light weight. With Vne at 75 mph, the Aero-Lite 103 will run only 63 mph in level flight, exactly as proscribed by Part 103. Cruise speeds were comfortable around 50 mph. Climb reached 1,000 fpm at times (averaging about 800 fpm). If low-over-the-fields is a performance measurement, the Aero-Lite 103 shines.
Cons - As a Part 103 ultralight, the Aero-Lite 103 can't be a speed monster, and it isn't (though, personally, I don't consider this a negative). A later enclosed model might be faster, but probably won't fit Part 103.
Stability
Stall recovery and characteristics; Dampening; Spiral stability; Adverse yaw qualities.
Pros - Stalls were mild no matter how I did them. Speeds dropped down to 25 mph according to the on-board Hall wind speed meter (usually an accurate device). Adverse yaw was surprisingly little considering the control authority present. Longitudinal stability checks were positive, recovering quickly enough. Adverse yaw is fairly mild for the size of control surfaces.
Cons - Stalls would break when aggravated. Took quite a lot of back pressure to hold steep turns. With engine up high, adding power pushes the nose down (opposite of "conventional," though common on ultralights).
Overall
Addresses the questions: "Will a buyer get what he/she expects to buy, and did the designer/builder achieve the chosen goal?"
Pros - The value provided by the Aero-Lite 103 is so good it makes many other ultralights look expensive. Terry Raber also made his debut model look very good; the sail covering was superb (I'd sure let him build mine!). New manufacturer, but one with experience and delivery promise of two units per month sounds honest.
Cons - Yes, it's only a single-seater; live with it. It's hard to come up with overall negatives for this well-achieved machine.