Welcome to Hayes Aero Ultralight and
Light Sport Aircraft


Aerolite 103 now avaliable from Hayes Aero LLC

Aerolite Kits and Ready to Fly


Airframe Kits 

Starting at $10,800

In Stock July 2018

This Plane with Hirth F33, Wheel pants, Strut and gear leg fairings...

 As a quick build Kit $16,400.

Ready to Fly...$20,260.

Other engines and options available.

Avaliable July 2018

Dealers Demo

Custom Sails

Hirth 2702, Gear leg and Strut fairings, Hydraulic brakes with 13x5x6 wheels, Wheel pants, Grand Rapids EIS, 10 Gallon fuel tank.

As a Quick build Kit $19,304.

Kits in Stock July 2018

Kits in Stock July 2018

Order your Sail colors and Engine options.


Basic Kits in Stock

add your Options


Check Option page for Engine and color selection.

Video Links

Informative Interview with Dan Johnson at Sun-N-Fun, 2013

Aerolite 103

Aerolite 103


The Aerolite 103   is available as a professionally built, ready-to-fly, legal   Part 103 single-seat ultralight aircraft,   or as a Quick-Build Kit that you can assemble yourself.

Standard equipment   on every Aerolite: 

Complete     airframe,   featuring your choice of sail color(s), Nose Fairing & Windscreen, Instrument Panel, Electric Flaps, Shock   Absorbing Main Gear, Steerable Nose Wheel   with Suspension, Four-point Restraint System, 5 Gallon Aluminum Fuel Tank, Visual   Fuel Quantity Gauge, Dacron Covering,   Azusa Brakes,   and a Fully Anodized Airframe.

All   Factory Built Ready-To-Fly Aerolites include all of the above,   plus   Engine (see engine choices below), Reduction Drive, Electric Start, Lightweight Lithium   Starter Battery, 2   Blade Culver Prop Propeller, Complete Panel   with flight and engine instrument (airspeed, altimeter,   slip indicator, tachometer, EGT,   CHT).

HISTORY of the Aerolite 103



The Aerolite 103 was designed by long-time   aviation enthusiast Terry Raber, in 1996.  Everyone in the   Ultralight and Light sport industry knows Terry.  The vast   majority of the light aircraft flying use his Streamline Strut   Fairings and Stainless Exhaust Brackets (both of which he   designed back in 1993).  

In the early 1990's, Terry was   building and selling ultralights, but he always felt the perfect plane had not yet been designed.  Not   being one to settle for second best, he carefully studied   the best features of each ultralight.    Eventually, he put all the pieces together with his own   refinements to produce the Aerolite 103.  The first prototype   Aerolite 103 flew on October 6, 1996.  Testing continued while   building the production prototype and the Aerolite 103 debuted   at Oshkosh in 1997.    The Aerolite 103 was appropriately awarded the ultimate   prize of Grand Champion Ultralight.  Since   that day, the design has gone on to win multiple awards   over the years. 

Between 1997 and 2012, Terry produced   hundreds of Aerolite 103's.  The aircraft has always been   extremely popular and highly regarded by both experienced and   newer pilots alike.

In 2012, Terry made the difficult decision   to pursue other non-aviation business interests and decided it   was time for the Aerolite 103 design to have a new home.    Terry contacted U-FLY-IT Light Sport Aircraft's owner, Dennis   Carley to inquire if he had an interest in carrying on the   manufacturing of the Aerolite.  After a brief, yet very   productive conversation,  plans were implemented to   facilitate the relocation of the Aerolite production facility to   U-FLY-IT's base of operation in DeLand, Florida.

Dennis also has an extensive history of   building and flying Ultralight/Light Sport Aircraft.  He   too has received Grand Champion and other awards for his   craftsmanship that has been exhibited.  Having built over   100 Ultralight and Experimental aircraft in the past 20 years,   he was well suited and the perfect person to carry on with the   production of the Aerolite 103.  While working in the   capacity as a DAR, Dennis issued hundreds of airworthiness   certificates to all types of Ultralight, Experimental and   homebuilt aircraft.  He has consistently regarded the   Aerolite as one of the best designed and most rugged light   aircraft ever produced.

Production of the Aerolite 103 continues   to adhere to the highest aviation standards, delivering years of   safe pleasure flying to those who own or fly one.  It is   arguably the best value of any Ultralight Aircraft available!



                                       Type Legal Part-103 Ultralight   

                                          Configuration Single Place 

  Empty Weight      235 lbs 

 Gross Weight 600 lbs.  

  Length 16 ft. 3.25 in. 

  Wing Span 26 ft. 10.25 in. 

  Wing Area 121 sq. ft.  

 Wing Loading @ 450 Lbs. 3.72 lbs / sq. ft.  

 Wing Loading @ 500 Lbs. 4.13 lbs / sq. ft.  

 Wing Loading @ 550 Lbs. 4.54 lbs / sq. ft. 

 Wing Loading @ Max Gross Weight 4.96 lbs / sq. ft. 

  Design Load Limits @ Gross Weight +4 / -2  

 Engine Power Requirements 28 hp.-50 hp.  

 Propeller Max. Diameter 60 in   

 Stall Speed, Flaps Extended 26 mph

 Stall Speed, Clean 28 mph 

 Cruise Speed (2) 45-63 mph   

 Top Speed 63 mph 

 Rate Of Climb 500 - 1000 fpm   

 Sink Rate 350-400 fpm.  

 Roll Rate 45° to 45° bank / 2.5 seconds  

 Take Off Distance 100-200 ft.   

 Landing Distance 100-200 ft.  

 Fuel Capacity 5 U.S. Gallons   

Endurance 1.5-2.5 hours   

Fuel Consumption 2-4.5 US Gallons / hour   Range 80-120 miles         

Limitations &   V-Speeds 

  Vne (never   exceed) 70 mph.   

Va   (design maneuvering speed) 50 mph.   

Vfe  (max   flaps extended) 70 mph.  

 Vy  (best   rate of climb) 45 mph.   

Vx (best   angle of climb) 40 mph.  

 Vs  (stall,   flaps retracted) 28 mph  

 Vs  (stall,   flaps extended) 26 mph 

 Vr  (rotation   speed) 30 mph.  

 Max. Crosswind Component 15 mph

 Max. Wind Speed 25 mph. 

 Max. Bank Angle 45° 

 Max. Pitch Angle 30° 

Aerolite 103 colors



Choose colors from link below


Hirth Aircraft Engines

F-33 2 cycle 28hp


 The 2702 is our small high torque low RPM engine. Like it's big brother,  the 3202 it's a low RPM powerhouse, at an incredible 5500 rpm this  little engine is producing 40hp and it's pumping out 39ft/lbs of torque  at only 4500 rpm. The Hirth 2702 is ideal for single seat ultralight  aircraft. 

F-23 2 cycle 50hp

 f you prefer an opposed cylinder engine, then this one's for you. The  F-23 puts out an amazing 50hp at only 6150 rpm and provides 42ft/lbs. of  torque. All with a total weight of only 84 Lbs.. This engine can handle  any part 103 ultralight and most single seat experimentals. Opposed  pistons cancel out each others internal inertia forces resulting in an  amazingly smooth running engine. 

2702 2 cycle 40hp

 The 2702 is our small high torque low RPM engine. Like it's big brother,  the 3202 it's a low RPM powerhouse, at an incredible 5500 rpm this  little engine is producing 40hp and it's pumping out 39ft/lbs of torque  at only 4500 rpm. The Hirth 2702 is ideal for single seat ultralight  aircraft. 



About Hayes Aero

Back to my aviation roots


     Back in the 70's after playing around with hang gliders for awhile ultralights attracted my attention.  The Glider Rider publication started having stories about the Easy Riser and Quicksilver weight shift hang gliders.  They were adding go cart engines to become the first ultralights.  Many other manufactures were soon to follow.  This quickly got my attention as I saw it as an affordable way to get   into aviation with my minimum wage salary as an EMT.  Reading all that I could find about ultralights and watching the classified ads I found an Easy Riser ultralight with a 10 hp engine for sale nearby.  I purchased the ultralight and started looking for some advice on how to fly it.

    I found a local ultralight club at Almont Airport, The Almont Flyers and joined the group.  I was quickly talked out of trying to fly the Easy Riser and purchased a damaged SR1 Hornet biplane ultralight to rebuild.  Thus began the start of my aircraft building bug that I haven't been able to shake!

The Almont Flyers club disbanded and many of the members joined The Michigan Ultralight Association (MULA) as I did.  I also wanted to expand my options by getting my private pilots license which I did at Big Beaver Airport in Troy. Michigan.  Making many new friends and attending local and national ultralight fly-ins was a lot of fun in my low and slow ultralights.

   After owning, building and repairing many ultralights, I became a Basic Flight Instructor (BFI) for ultralights when the Part 103 training exemption came out.  I trained many pilots to fly in my Quicksilver and Rans S-12 ultralight trainers, always enjoying the look on there faces when they mastered another task.

   The 103 exemption went away along with the ability to train new students in a two place ultralight.

The new affordable (???) way to fly and get training had arrived with the new Light Sport Aircraft and Sport Pilot's license.  Other opportunities came with the Light Sport rules;  receiving my Light Sport Repairman certificate, getting all of the Rotax ratings that I could, and becoming a Light Sport CFI.  I then started Hayes Aero LLC.

    I went to Rans Aircraft in Hays Kansas to see about building ELSA Rans S-19's.  I purchased a kit and built the first Rans ELSA S-19.  Thus becoming a Rans dealer and builder.  The flight school at the airport I was working out of had two of my Rans trainers in it, a Rans S-6 and S-7.  Students and instructors were looking for something with a little more general aviation look to train in.  With that in mind I purchased a Sling 2 from The Airplane Factory.  Along with two of the instructors we started Midwest Sky Sports. The business took off quickly!  We were soon building SLSA aircraft and doing builder assist.  

    Looking to slow down and spend more time with family and grandkids I sold my portion of the business to my partners. 

    The comeback of interest in affordable ultralights reignited my passion for the experience of the low and slow flight.  It didn't take long to see all of the attention that the Aerolite 103 was getting.  After   doing my research I discovered a reputable company (Aerolite 103, LLC) with a quality product.  I contacted the manufacturer Dennis Carly about becoming a dealer.   After purchasing a display trailer full of kits I am now an Aerolite 103 dealer!

    Coming back to my aviation roots... I look forward to being a part of the comeback and interest of affordable fun low and slow flying of ultralight aircraft!

Rick Hayes

Hayes Aero LLCLLC


Jenny Replica plans built by Rick Hayes


Aerolite 103

Michigan Ultralight Association


Unites States Ultralight Association


Aero Sports Connection


Aerolite 103 Facebook


Rans Wing Assembly

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Hayes Aero

(248) 462-9338