Ultralight aviation provides an excellent pathway for those who want to fly, but don’t want to get licensed. These quite often cheap and cheerful DIY aircraft often hide some excellent engineering underneath. This is no more true than in [ultralight helicopter’s] four-year-long helicopter build saga!

While most ultralight builds are fixed-wing, a rotocraft can meet all the legal definitions of ultralight aviation. This helicopter is an excellent example of what’s possible with a lot of time and patience. The construction is largely aluminium with some stainless steel on the skids. A 64-horsepower Rotax 582UL engine powers the two-bladed main rotor and tail rotor. The drivetrain features a multi-belt engine coupler and three gearboxes to ensure correct power output to the two rotors.

It features a control layout familiar to any helicopter pilot with foot pedals that control the rotor pitch for anti-torque control. A cyclic in front of the pilot controls the rotor’s cyclical movements, resulting in forward and sideways flight control. A collective with integrated throttle controls the overall main rotor pitch for altitude and climb control. Finally, a simple clutch sits next to the collective for engine start and idles.

The build was meticulous, with nearly everything from the swashplate to the gearboxes custom-machined. The balance and alignment of everything, from the rotor blades to the input trim, had to be checked. The build is a masterpiece of home workshop engineering.

We’ve seen ultralights before, so make sure to check out this electric fixed-wing ultralight next! Or, if you want really light, try foam.

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