The Rotec Rally line has grown out of the solid aeronautical engineering and helicopter-rated experience of William Adaska. The pilot sits inside a roll cage in the manner of a stock car. The control column is pivoted from above so that in the event of a head on collision with the ground it pushes out of the way, instead of into the pilot’s stomach. The 48 hp engine is mount¬ed above and aft of the wing for pilot safety.

Rotec Rally Article

The Rotec Rally line-up are all equipped with standard rudder pedals and stick; providing three axis aerodynamics like any normal aeroplane. However, possibly be¬cause of the designer’s helicopter back-ground, the throttle is a twist-grip mounted on the control stick. All tubing is aircraft grade 6061-T6 anodised aluminium and hardware is aircraft quality AN material. Cables are aircraft grade stainless steel 7 x 7 vinyl coated.

Accompanying each aircraft is a 145 page assembly manual and a 95 page pilot’s manual that covers all aspects of microlight flying. Different sized wheels are available. The standard size is the 20” which would give the Rally Sport an even higher ground clearance than the 4” wide 16” ‘Tundra” tyres; fitted to decrease side loads during cross wind landings and take the bumps out of rough ground and river bed landings. The Rally 3 was even higher; 13.5 inches.

The Rally models could be derigged for transport on a trailer and rerigged in about 45 minutes. All slip pins were safety locked with split rings. The trailing tail wheel is bungee. Spoilerons are held down by a bungee cord which makes for a positive feel in flight. The 48 hp engine is fan cooled making for efficient cooling and the “see through” 5 gallon fuel tank provides about 2 and a half hours endurance at normal revs.

The wing is a single surface of 3.8 oz dacron, available in a variety of colours already sewn at the factory.

Special custom sails are available. End plates add to the lifting capacity. Maximum “G” for the Sport is given as plus six and minus three.

Elevators are described as being “Butter¬fly” to provide strong pitch control for rapid aerobatic manoeuvres. The elevator sur¬faces surrounding the sides and trailing edge of the stabiliser are aerodynamically balanced to allow minimal force on the con¬trol stick at all speeds. Each Rally can have its controls set to suit the pilot. There is an optional adjustable seat which allows the pilot or the passenger to slide into the most comfort¬able position. The joystick is adjusted by the simple method of tightening or loosening the control cables.

The Rally 1 is a high-wing monoplane with con¬ventional tail unit much like the Rally 2B. Rather than stick and pedal controls, the weight shift is used for roll and pitch control, with the pilot in a sling seat. POWERPLANT: Zenoah in pusher position above the wing, and a 2.4:1 reduction unit. Otherwise similar to Rally 2B. LANDING GEAR: Similar to Rally 2B. Top mounted joy stick, rudder pedals, castering tailwheel. First built; 1976.

The Rally 2B is a high-wing monoplane with con¬ventional tail assembly consisting of horizontal and vertical stabilizers. The elevators are separate and the rudder is all ¬flying. Roll is controlled by ailerons and can be operated separately from the foot-controlled rudder by means of an inverted control stick. Construction makes use of aluminum tubing and steel aircraft cable. The wings and tail surfaces are covered with Dacron with clear windows at both wing roots. The engine is mounted in a pusher position above the wing. A 2.4:1 reduction unit turns a two-blade wooden propeller made by Rotec. Fuel is carried in an ABS plastic tank hung under the wing root area. LANDING GEAR: Conventional taildragger gear are shock mounted with bungee wrap. The tailwheel is castering, and the main wheels measure 20 inches in diameter. There are no brakes. The Rally 2B was first built in 1976 and by June 1981 500 had been delivered.

The United States Marine Corp have bought the Rally 2B, as have the Department of the Interior Geological Sur¬vey Team.

The 1981 standard version of the Rally 2B used ailerons attached to the trailing edge of the outer sections of the wing. This method was dropped in favour of spoilerons carried on the upper surface of the wing and mounted at 1/3 chord back from the leading edge. The Rally 2B is sold as a kit for $4800 in March 1983, options including an instrument panel, transport covers for $350, floats $950, skis $280, windshield $72 and transparent panels for the first third of the span of each wing $150. The Rally 2B is sold ready built for an extra $680.

The Rally 2B Twin is similar to the Rally 2B. POWER-PLANT: Zenoah-Twin mounted in a pusher position above the wing. A 2.4:1 reduction unit turns a two-blade wooden pro¬peller made by Rotec. Otherwise similar to the Rally 2B. LANDING GEAR: Similar to the Rally 2B. The aircraft is also available in 2B+ form, with a different wing design incorporating extra ribs and more camber and billow, a combination which Rotec says gives better pitch stability.

The 2B is a three axis design and initially used the same engine as the Rally 2, but various other units were substituted, including a Solo with 2.7/1 reduction drive, developing 20hp at 5200rpm, (the 2B1 version) and a twin cylinder 292cc 30hp Chaparral unit (the 2B2 version, sold in the US with floats, under the name Rally Marine). Some aircraft were also made with the 28 hp Kohler engine.

In 1983, customers had the choice of 40 hp Kawasaki, 35 hp Cuyuna or 32 hp Rotax engines.

The Rally Marine is similar to Rally 2B. POWERPLANT: Zenoah-Twin mounted in pusher position above the wing. Similar to the Rally 2B Twin. LANDING GEAR: Standard gear are replaced by two 9-foot foam pontoons.

The Rally Sport has roll control by three quarter span spoilerons; suspension on all wheels. Announced on 1 March 1983, this single seater from Bill Adaska is, according to the company, ‘an optimised airplane rather than an innovative airplane’. In fact, apart from an obvious family resemblance, the Rally Sport does not have a great deal in common with the earlier Rallys. Certainly its performance characteristics are very different, particularly its maximum roll rate, which is quoted as 150 deg/s.

The Rally Sport is offered, after a year of test flights by its manufacturer, as an acrobatic ultralight. The wing design is considerably changed from the 2B, with smaller span and area and saumons at the tips, while a dramatic roll rate comes from three quarter span spoilers, compared with one third span for the 2B. The tail uses aerodynamically balanced elevators which surround the edges of the horizontal stabiliser giving the effect of servo tabs. Power comes from the Rotax 503, used in the same form as on the Rotec two seater, the Rally 3B. The machine was sold as a kit for $5600 or ready to fly for an extra $680 in 1982. There is an option of transport covers for $325. Shorter wing and airframe beefing gives Rally Sport a load factor of + 6, -3 G’s for aerobatics. With a top mounted joy stick, rudder pedals, castering tailwheel, the Rally Sport was first built in 1976.

Developed for the Rotec Rally is a spray system carrying 24 gallons and with spray booms attached to the wings to provide a 45 foot spray pattern. With an application of three gallons per minute while flying at 30 mph, the Rally should cover 2.7 acres a minute.

The Rally 3 is a side by side two seater version of the Rally 2B, with conventional 3 axis controls. Roll control by spoilerons. Nylon rope suspension on all wheels. This two seat version of the Rally is sometimes known as the Big Lifter and received FAA experimental certification on 18 November 1981, after more than 12 months’ trials by Rotec, first sales being the following January.

It differs from the single seat 2B mainly in having an enlarged framework, with a third cranked tube running longitudinally, and an enlarged span, though the chord remains the same. As on the Rally Sport, the horizontal stabiliser uses aerodynamically balanced ‘ser¬vo tabs’. Originally powered by the Cuyuna 430R, the aircraft now comes with a Rotax 503 for which 48 hp is quoted.

At the end of 1982 Rotec announced what it calls the ‘jump option’ under which the aircraft was converted to carry a parachutist. This is done by removing the second set of pedals and adding a sliding seat and trapeze bar, while for jumpers who prefer to start their descent from a standing position, a platform can be fitted.

The two main wheels of the Rally 3 can be replaced by mahogany skis with a glass fibre surface as a $320 option, while saumons as on the Rally Sport can also be added as an extra. Further options include transport covers for $450, floats for $1250 and a windshield for $116 (in 1982).

Although offered in January 1983 for $5000, the normal price of a Rally 3 in standard form is $6000 as a kit; it is not available ready built in the US because it is classified as an experimental aircraft under US legislation. The United States Army has purchased 300 of the Rally 3 with a 500 lb payload which would typically consist of two persons and some weapons and features a minimum cruise speed of 45 mph with a range of 200 nm on 16 gallons of fuel. The Army required the aircraft to have a 10,000 foot ceiling, rough field landing capability and to be capable of assembly out in the field by two persons in 30 minutes.

Elsewhere it can be bought ready built for an extra $960, while in France, where it is imported to special order only and known as the Rally 4B2S, it is fitted with a Hirth 276R engine developing 36hp at 6250 rpm.

Feb 2014
wraupert@namibnet.com
Can someone please help me with a pdf-copy of an assembly manual for the Rotec Rally 2b, mine got lost and i would like to put my Rally together and fly it again.
Thanx alot in advance! regards,
Werner

Rally 1
Engine displacement 240cc
Rated HP, 20 hp
Static thrust, 170 lbs
Wingspan, 31 ft
Wing area, 155 sq.ft
Aspect ratio, 6.4:1
Overall length, 14.5 ft
Empty weight, 125 lb
Usable payload (include fuel), 232 lb
Wing loading, 2.3 lbs/sq.ft
L/D power-off glide ratio, 7.5:1
Cruise speed (85% power), 34 mph
Stall speed, 16 mph
Approach speed, 25 mph
Flair speed, 20 mph
Liftoff speed, 18-20 mph
Takeoff roll distance, 90 ft
Rate of climb, 400 fpm
Fuel capacity, 2 USgal
Range at cruise, 60 mi
Seats: 1

Rally 2B
Engine Zenoah, displacement, 240cc, 20 hp
Static thrust, 170 lb
Wingspan, 31 ft
Wing area, 155 sq.ft
Aspect ratio, 6.4:1
Overall length, 15.7 ft
Empty weight, 135 lb
Usable payload (include fuel), 232 lbs
Wing loading, 2.4 lbs/sq.ft
L/D power-off glide ratio, 7:1
Cruise speed (85% power), 32 mph
Stall speed, 16 mph
Ap¬proach speed, 25 mph
Flair speed, 20 mph
Liftoff speed, 18-20 mph
Takeoff roll distance, 90 ft
Rate of climb, 350 fpm
Fuel capacity, 2 Usgal
Range at cruise, 60 mi

Engine: Cuyuna 430R, 35 hp at 5500 rpm
Propeller diameter and pitch 54 x 32 inch, 1.37 x 0.81 m
Toothed ¬belt reduction
Power per unit area 0.22hp/sq.ft, 2.4hp/sq.m
Fuel capacity 3.5 US gal, 2.9 Imp gal, 13.2 litre
Length overall 16.8 ft, 5. 13 m
Height overall 10.3ft, 3.15m
Wing span 31.0ft, 9.44m
Constant chord 5.0 ft, 1.52 m
Total wing area 155sq.ft, 14.4sq.m
Rudder area 12.3sq.ft. 1.14 sq.m
Total elevator area 7.6 sq.ft, 0.70 sq.m
Wing aspect ratio 6.2/1
Main wheels diameter overall 20 inch, 51 cm
Empty weight 218 lb, 99kg
Max take off weight 466 lb, 211kg
Payload 248 lb, 112kg
Max wing loading 3.00 lb/sq.ft, 14.7 kg/sq.m
Max power loading 13.3 lb/hp, 6.0kg/hp
Load factors +3.0, 1.5 design; +3.8, 2.0 ultimate
Max level speed 50 mph, 80 kph
Never exceed speed 55 mph, 88 kph
Max cruising speed 40 mph, 64 kph
Economic cruising speed 35 mph, 56 kph
Stalling speed 19 mph, 30 kph
Max climb rate at sea level 680 fpm, 3.5 m/s
Min sink rate 275 fpm, 1.4 m/s
Best glide ratio with power off 7/1
Take off distance 75 ft, 23 m
Land¬ing distance 50 ft, 15 m
Service ceiling 10,000ft, 3050 m
Range at average cruising speed 78 mile, 125 km

Engine: Rotax 377, 38 hp at 6600 rpm
Propeller diameter and pitch 54 x 34 inch, 1.37 x 0.86 m
Toothed ¬belt reduction, ratio 2.2/1
Max static thrust 280 lb, 127 kg
Power per unit area 0.25hp/sq.ft, 2.6hp/sq.m
Fuel capacity 5.0 US gal, 4.2 Imp gal, 18.9 litre
Length overall 16.8 ft, 5. 13 m
Height overall 10.3ft, 3.15m
Wing span 31.0ft, 9.44m
Constant chord 5.0 ft, 1.52 m
Total wing area 155sq.ft, 14.4sq.m
Rudder area 12.3sq.ft. 1.14 sq.m
Total elevator area 7.6 sq.ft, 0.70 sq.m
Wing aspect ratio 6.2/1
Main wheels diameter overall 20 inch, 51 cm
Empty weight 218 lb, 99kg
Max take off weight 466 lb, 211kg
Payload 248 lb, 112kg
Max wing loading 3.00 lb/sq.ft, 14.7 kg/sq.m
Max power loading 12.3 lb/hp, 5.6kg/hp
Load factors +3.0, 1.5 design; +3.8, 2.0 ultimate
Max level speed 50 mph, 80 kph
Never exceed speed 55 mph, 88 kph
Max cruising speed 45 mph, 72 kph
Stalling speed 19 mph, 30 kph
Max climb rate at sea level 700 fpm, 3.6 m/s
Best glide ratio with power off 7/1

Rally 2B Twin
Engine Zenoah twin displacement, 300cc, 30 hp
Static thrust, 255 lb
Wingspan, 31 ft
Wing area, 155 sq.ft
Aspect ratio, 6.4:1
Overall length, 15.7 ft
Empty weight, 170 lb
Usable payload (include fuel), 270 lb
Wing loading; 2.8 Ibs/sq.ft
L/D power-off glide ratio, 6.5:1
Cruise speed (85% power), 44 mph
Stall speed, 18 mph
Approach speed, 25 mph
Flair speed, 20 mph
Liftoff speed, 18-20 mph
Takeoff roll distance, 70 ft
Rate of climb, 800 fpm
Fuel capacity, 4 USG
Range at cruise, 110 mi

Rally 3
Engine: Rotax 503, 48 hp at 6250 rpm
Propeller diameter and pitch 60 x 28 inch, 1.52 x 0.71 m
Toothed belt reduction, ratio 2.3/1
Max static thrust 338 lb, 153 kg
Power per unit area 0.25 hp/sq.ft, 2.7 hp/sq.m
Length overall 17.3 ft, 5.28 m
Height overall 10.7ft, 3.25m
Wing span 38.0ft, 11.58m
Constant chord 5.0 ft, 1.52 m
Total wing area 190sq.ft, 12.7 sq.m
Wing aspect ratio 7.6/1
Main wheels diameter overall 16 inch, 41 cm
Empty weight 265 lb, 120kg
Max take off weight 695 lb, 315kg
Payload 430 lb, 195kg
Max wing loading 3.66 lb/sq.ft, 17.8 kg/sq.m
Max power loading 14.5 lb/hp, 6.6 kg/hp
Max level speed 45 mph, 72 kph
Max cruising speed 40 mph, 64kph
Stalling speed 20mph, 32kph
Max climb rate at sea level 450 ft/min, 2.3 m/s
Best glide ratio with power off 7/1
Take off distance 100ft, 30m
Landing dis¬tance 80ft, 25m
Service ceiling 10,000ft, 3050m
Range at average cruising speed 100 mile, 161 km

Rally 3 Big Lifter
Engine – 2 cyl two stroke: 48 hp
Wing Span: 38 ft
Wing Area: 190 sq ft
Length: 17′ 4″
Height: 10′ 8″
Cruise Speed: 40 mph
Max Speed (Vne): 50 mph
Max Range Standard: 100 miles
Stall Speed (100% Power): 20 mph
Stall Speed – Power Off: 22 mph
Take-off Distance: 100 ft
Landing Distance: 80 feet
Rate of Climb s/l: 450 fpm
Ceiling: 10,000 ft
Glide Ratio: 7.1
Wing Loading: 3.2 lb/sq ft
Empty Wt: 285lb
Max Payload: 430lb

Rally Champ
Engine: Rotax 277 (268 cc) 28 hp
Static thrust: 200 lb
Empty wt: 202 lb
Wing span: 31’
Wing area: 135 sq.ft
Height: 10’4”
Length: 16’10”
Fuel cap; 3.5 USG
Construction: Aluminium, Dacron
Max wt: 427 lb
Stall: 18 mph
Max speed: 45 mph
Vne: 50 mph
Climb rate: 450 fpm @ 30 mph
Glide ratio: 7.5-1
Wing loading: 3.16 lbs/sq.ft
Power loading: 15.25 lbs/hp

Rally Marine
Engine displacement, 300cc, 30 hp
Static thrust, 255 lb
Wingspan, 31 ft
Wing area, 155 sq.ft
Aspect ratio, 6.4:1
Overall length, 16 ft
Empty weight, 220 lb
Usable payload (include fuel), 250 lb
Wing loading, 3 lbs/sq.ft
L/D power-off glide ratio, 6.5:1
Cruise speed (85% power), 40 mph
Stall speed, 18 mph
Approach speed, 25 mph
Flair speed, 20 mph
Liftoff speed, 18-20 mph
Takeoff roll distance, 90 ft
Rate of climb, 650 fpm
Fuel capacity, 4 USG
Range at cruise, 100 mi

Rally Sport
Engine: Rotax 503, 48 hp at 6250 rpm
Propeller diameter and pitch 60 x 28 inch, 1.52 x 0.71 m
Toothed belt reduction, ratio 2.3/1
Max static thrust 338 lb, 153 kg
Power per unit area 0.36 hp/sq.ft, 3.8 hp/sq.m
Fuel capacity 3.5 US gal, 2.9 Imp gal, 13.2 litre
Length overall 16.6 ft, 5.05 m
Height overall 10.4ft, 3.15m
Wing span 27.0ft, 8.23m
Constant chord 5.0 ft, 1.52 m
Total wing area 135 sq.ft, 12.5 sq.m
Wing aspect ratio 5.4/1
Empty weight 248 lb, 112kg
Max take off weight 468 lb, 212kg
Payload 220 lb, 100kg
Max wing loading 3.461b/sq.ft, 16.9kg/m
Max power loading 9.8 lb/hp, 4.4kg/hp
Load factors; +6.0, 3.0 ultimate
Max level speed 60 mph, 97 kph
Never exceed speed 60 mph, 97kph
Max cruising speed 50mph, 80kph
Stalling speed 20 mph, 32 kph
Max climb rate at sea level 1000 ft/min, 5.1 m/s
Best glide ratio with power off 6.8/1
Take off distance 70ft, 21m
Landing dis¬tance 75ft, 23m
Service ceiling 10,000ft, 3050m
Range at average cruising speed 83 mile, 134km
Roll rate: 150 deg/sec

Rally Super Sport
Cruise Speed: 50 mph
Max Speed (Vne): 60 mph
Max Range Standard: 83 miles
Stall Speed (100% Power): 20 mph
Stall Speed – Power Off: 23 mph
Take-off Distance: 70 ft
Landing Distance: 75 ft
Rate Of Climb s/l: 1000 fpm
Ceiling: 10,000 ft
Max G-Load: + 6, -3g
Max Roll Rate: 150 deg/sec
Glide Ratio: 6.81
Wing Loading: 3.3 lb/sq ft
Power Loading: 9.31 lb/hp
Wing Span: 27 ft
Wing Area: 135 sq ft
Length: 16′ 7”
Height: 10′ 4″
Engine – 2 cyl two stroke, 48 hp
Empty Wt: 248lb
Max Payload: 220lb