When we looked at the crowded aircraft tug market a couple of years ago, we found that battery-powered electric models dominate for overall reliability and cold-weather ops.
So after moving to an airport where I now need to move my own 3500-pound piston single in and out of a hangar, I set out to build a short list of top contenders. Here I’ll share some tips for shopping, how you might make the right decision (these things cost a fortune to ship) and the electric models that I think are standouts for features and capabilities.
The Basics
Like with smaller drill-powered tow bars, you should consider the manufacturer’s warranty and how much it will cost to ship for service, its traction on snow and ice, its power to climb inclines, its speed, the time between battery charges and the overall life span of the battery and their replacement cost. There’s also the type of electrical circuit required to charge the tug (220 volts, as an example), the adapter that might be required for your specific aircraft, built-in safety features and optional features like an onboard GPU and air compressor.
And fit is a huge consideration because some tugs attach to the nosewheel much like a tow bar, while others winch the aircraft’s nosegear onto a raised platform. This provides less stress on the wheel and doesn’t usually require adapters. Manipulating the aircraft while under tow is similar to a mechanical tow bar— apply power and turn the tug. Some manufacturers offer a Lazy Suzan option, which allows the tug to turn without turning the nosegear. This feature should protect the turn limits of the nosegear from costly damage.
New to the category are so-called radio-controlled-towbots, which lift and pull from under the nosewheel or tailwheel. With the right motor and drivetrain combination, pushing, pulling and turning an airplane by remote control isn’t for the unccordinated, as simple as it looks. To drive, push the stick forward and aft. With the joystick in the left corner, the towbot will turn left—airplane go? Try one during a thorough demo.
Models from AC Air Technology use a tank-like continuous track tread and a wide footprint. Our experience is that the large surface area of the tracks helps to distribute the weight of the tug better than steel or rubber tires of an equivalent tug. The benefit there is they keep chugging through mud and soft grass without getting stuck. If you operate out of a grass strip, we think track treads are tops.
Regardless of terrain, take a tug for a test run before buying it, where you might spend a small fortune to have it shipped. At AirVenture last year there were three electric tug makers displaying their products—some on actual aircraft. New to powered tugs? Some coordination is required and that’s one reason to try it out, first.
While the direct-attach tugs or electric tow bars require the similar hand/eye coordination as using an unpowered tow bar, a remote-control towbot requires some skill, especially in a tight hangar. Post-purchase pro tip: Practice with the aircraft on the ramp, free of obstacles, and use spotters (helpers) until you get the hang of towing in and out of a tight hangar. Consider painting bright centerlines on the apron and in the hangar for proper alignment.
Here’s a summary of a handful of standout electrics.
AirTug
Around since 1974 and purchased by new owners in 2022, Ohio-based AirTug has 11 models based on three models powered by electric motors or gas engines. AirTug says sales of gas and electrics have been an even split, with some customers adamant about using gas engines over electric, which are likely commercial operators (shops and FBOs) moving a lot of planes each day.
The batteries for the NFE- and EL-series electric models are standard 12-volt AGM gel-filled lead-acid. Lithium batteries can be used, but the standard battery charger is not compatible. Runtime is roughly one hour between charges, and the $225 batteries have been lasting as long as five years before needing replacement. The drill is to keep these tugs plugged in when not in use so the battery is always topped off when you need it. Think electric golf cart.
Some of the models include a hydraulic lift to help larger aircraft rudders clear smaller hangar doors. AirTug says the tugs can handle inclines up to 5 degrees, and there are options and adapters for planes with wheel pants, extension plates, a night lighting kit, an adapter for uncowled aircraft, tailwheel chocks and a weight pack for extra traction when tugging planes that are light in the nose.
A safety feature keeps the tug’s brake engaged unless the tug is in motion. When you release the thumb throttle, the brake automatically engages. User controls are simple, with an on/off switch at the top of the control handle. The thumb throttle operates the transaxle, which provides variable control of the tug speed. When trying out a tug, you want to test the accuracy of its variable speed control because you’ll need it when carefully dancing the plane around in tight quarters and for moving over lips on the surface with coordination.
For speed-bump-sized lips, consider using ramps. It could save on pricey repairs because braking too abruptly from a higher speed can seriously damage the differential ring gear, which is considered abuse and will not be covered by the transaxle warranty. Ongoing maintenance requires tire pressure checks, plus the caster fittings and drive chain require periodic lubing.
Prices for AirTug electric models start at $3845 for the NFE-4 (plus shipping), which will tug castering or non-castering nosewheel airplanes 4000 pounds or lighter, to the $5275 EL8-H for models less than 8000 pounds. The lighting option is $99. To help defray shipping costs, AirTug has established relationships with several international distributors to pass on savings through container shipping of their most popular products for European and Canadian customers. Visit www.airtug.com.
DJ Products
Minnesota-based DJ Products has been manufacturing motorized moving products for the warehousing, trucking, RV and aircraft industries for over 25 years. The aviation tugs were originally marketed by the Lindbergh Aircraft Tug Company. However, DJ Products is replacing the branding. With seven models in the AircraftCaddy line, the tugs can pull aircraft from under 4000 pounds to ones up to 35,000 pounds and utilize twist-grip control handles. Tug speed ranges from 0 to 3 mph, depending upon the model.
For typical GA aircraft, the AircraftCaddy 4K Jr., 4K/8K and 15K models cover a wide swath of aircraft, including ones with wheel pants. The 4K Jr. (for towing aircraft up to 4000 pounds) uses an arm that attaches to the aircraft wheel much like a typical towbar. The 4K Jr. has three wheels, which can be handy for more easily moving it to the aircraft. It might also simplify maneuvering/turning the aircraft while it’s attached.
It uses two 12-volt sealed batteries; keep them plugged in when the tug is parked and the onboard smart charger keeps the batteries maintained. The batteries are expected to have a two- to three-year life span (typically costing $100 or more each and can be purchased locally), while the tugs themselves have between an eight- to 10-year life. With the weight of the steel tug, batteries and motors, these tugs generally have good traction when on snow and ice, and the company offers snow tires and chains.
For safety features, the AircraftCaddy tugs have an emergency stop button, a safety horn, safety lighting and an auto-braking system. Prices range from $3000 to $25,000 depending upon the model.
In early February 2024, DJ Products launched a new Magic Arm product. The Magic Arm allows the nosegear to roll up onto the tug without the operator bending down. It’s available as an option for the 4K, 8K and 15K tugs. Currently, the Magic Arm cannot be ordered as a retrofit to an existing DJ Products tug, but the company is considering offering it as an upgrade to older tugs. There’s a one-year warranty and a two-week demo program with a money-back guarantee. Call them at 800-686-2651 (www.djproducts.com) for specific pricing and model specifications for the aircraft you intend on using it with.
Best Tugs
Utah-based Best Aviation Products was founded in 2016 by Mark Patey, who built a tug to make the airport experience easier for his wife. Patey has owned 46 aircraft (building 15 of them) and is the designer and builder of Scrappy and Draco STOL aircraft.
Patey leveraged his experience with digital controllers to build a unique tug control system after overstressing the nosegear on his Piper Meridian, causing $40,000 of damage. Essentially, the digital control system controlling the Best Tug’s electric motor will deliver 100 changes per second to the motor, changing torque to maintain a constant speed regardless of the environment—even delivering reverse torque if the system senses a downslope. While most competitors will require customers to upsize to a model based upon the aircraft’s max takeoff weight and operating conditions, Best simply requires customers to select a tug based upon the weight of the aircraft.
The smallest tugs are in the Alpha line, and the A1 model handles aircraft up to 2600 pounds. It folds for easy storage and is compatible with wheel pants and tailwheels. The A1 requires the operator to attach the tug manually, while the A2 and A3 models have clamping levers. These tugs have the smart torque/autothrottle controls that limit stress on the nosegear while turning.
Best’s Bravo line starts with its smallest model that can handle up to 4000 pounds, delivering 1600 watts of continuous power, peaking to 3200 watts as needed. Battery endurance is exceptional in this class, with the Bravo 5 moving an aircraft 40 to 50 times between charges. The Bravo product line goes all the way up to a 24,000-pound-capable tug.
Best Tugs uses sealed lead-acid batteries in its models because it wants the added weight for better traction. Recharge time from a flat battery to full charge is six hours, with a battery having a three- to five-year life span. Every Best Tugs model ships with a smart charger.
The Best Tugs machines have a number of safety features, including an automatic-shutoff throttle, auto-braking (in case the operator falls over, for example) and auto-chock—which will lock a parking brake and the gear set on the transmission. There’s also traction control and anti-lock braking.
There’s a kick-and-stow 45-degree control handle, which rotates up 90 degrees to store the aircraft on the tug in the hangar. With some models, the tug will fit underneath the propeller spinner. Models like the Bravo line use a retaining strap and a winch to pull the aircraft onto the tug. Best Tugs also offers a variety of adapters and yokes for specific aircraft. Some models include a GPU and air pump—two practical accessories.
The company recently released the Romeo line of towbots, capable of moving aircraft between 5000 and 18,000 pounds and operate via radio control.
The RC transmitter is designed similarly to the ones used with RC model cars, using a trigger (for speed) and a wheel (for directional control). At AirVenture last summer, I had operated the Bravo B5 model in the company’s booth and found it easy to use and steer, especially in the close confines of the exhibit area.
The Best Tugs models start at around $2600 for the lower-end Alpha A1 and upward of $49,000 for the Sierra S30, designed to move aircraft up to 99,000 pounds.
Best has 28 different models for a wide variety of applications. For example, a Cirrus SR22 can be accommodated by an Alpha A3, Bravo B4 and B5. While the A3’s goal is affordability, traction and steering may be an issue as it’s a dragger design. I’m told that 73 percent of their Cirrus customers chose a B5 ($6900, plus shipping) as the Bravo models are easier to maneuver and steer, with the aircraft’s nosegear positioned right over the traction wheels. Most service issues can be resolved in the field by the tug’s owner, including battery changes, which cost $60. Best Tugs only sells direct, with shipping costs varying from $300 to $1000 depending upon the tug model and destination.
Best Tugs also offers used competitors’ tugs for sale (trade-in inventory); however, rarely do they have used tugs for under $2000. On the horizon, Best has 14 new tugs on the drawing board, including a new Sierra S120 capable of moving up to 120,000 pounds.
Best Tugs is working on two new products, which are not tugs and are expected to be announced in the next four months. Best has chosen to be a bit secretive on these new products, having worked on them for some time. Stay tuned. In the meantime, visit them at www.besttugs.com.
AC Air Technology
Chino, California-based AC Air Technology emerged in 2012 with the company founder developing the T1 tug to support his own fleet of aircraft. All AC Air tugs are towbots, incorporating a continuous tread design with an RC transmitter. They are the world’s first patented remote-controlled aircraft tug. Their first model (T1) was lightweight, weighing 50 pounds and able to move a 3500-pound aircraft. At that time, there was not a lot of customer interest in a portable tug, but that changed with the introduction of the T1X4 (a medium-sized tug), designed to be taken apart into four components and transported in your aircraft (perfect for owners with multiple home bases).
AC Air has nine different tugs, with a variety of options. All are radio controlled via a transmitter that RC model aircraft pilots will be familiar with. The transmitter has removable rechargeable batteries (charger included), and the tug designs are all pretty similar, using two rugged tracks rather than wheels or rollers.
AC Air models can accommodate aircraft with a max takeoff weight between 2000 and 21,000 pounds, with prices starting from $4595 on the low end to $11,950 for larger flagship models. Their T1X3 has a Lazy Susan, allowing the nosegear to remain stationary while the aircraft is being moved. A tailwheel option ($115) can be added to any of the AC tugs. Navigating the AC product line is tricky. When trying to figure out what model may be best for you, consider that the different models are differentiated by longer wheelbases, the presence of a Lazy Susan, weight, portability and the width of the tracks. It’s good that AC Air offers a money-back guarantee during the first week of ownership, but you must pay for return shipping. (Keep in mind that these tugs weigh between 55 and 264 pounds, and it’s a two-person task to box and unbox.)
AC Air tugs ship with spare parts (a nice touch) including extra pins, links, retainer clips, treads, fuses, track install tools and a retainer clip tool. Depending upon the model, tire guide spacers are included. Operationally, the track tension may need to be adjusted after several hours of use. For those mechanically inclined, adjusting track tension requires removing six screws and a cover plate and loosening three retainer screws, followed by pushing the rail end forward using a small pry bar to tighten up the track.
While scanning the market at AirVenture 2023, I test-drove an AC Air model T1V2 pulling a taildragger. The demonstration area required moving the aircraft in a confined space with a tree, tent and other aircraft as obstacles. It was easy to quickly master operating the remote AC Air tug smoothly and accurately, moving the aircraft in and around the obstacles, much to the chagrin of AC Air’s Dan Haeggstrom. Worth mentioning is that AC Air’s customer support is favorable—an important consideration when buying any power equipment.
AC Air offers a variety of accessories including tire lifts, link conversion kits, adjustable cradles, an adapter for Cirrus models, Diamond DA40 constraint bars, storage bags, LED lighting and other pieces and parts. The tugs have a one-year warranty. New on the horizon is a helicopter tug for skid type helicopters with pricing starting at $25,200. Contact www.acairtechnology.com.
Purchasing decisions
As we said from the beginning, it’s critical to try before you buy. This will help you determine which of the many electric models will work best for you and the aircraft you intend on moving. One hangar or ramp bender can mean repair costs that are more than the tug.
Some vendors have a limited money-back guarantee, assuming that the returned device is in pristine condition. Most manufacturers do not cover return shipping. Still, tugs purchased through distributors like Aircraft Spruce (to name one trusted source) provide an opportunity to drop the tug off, rather than bearing the cost of shipping. Our advice is to contact the distributor to understand their return policies. With some tugs weighing between 150 to 250 pounds, the cost of shipping, especially internationally, can be $500 to $750 or more.
Upkeep is important, too. The best way to maneuver over an obstacle is to make sure the motorized tug’s tires are properly inflated and to take the aircraft over the bump one tire at a time. Try using a small wooden or metal ramp for the main tires and even for the nosewheel, if needed. Sporty’s sells a three-pack of hangar ramps, constructed of steel and painted bright yellow for enhanced visibility during the dark nights. At $149.95, they’re a useful addition to any hangar and help you maneuver the aircraft over the hangar lip without having to “take a run at it.” Also, consider power and traction because snow and ice on a ramp is a challenge for any tug. Snow tires and chains might be worthy accessories in northern states.
Last, we can recommend any of our top-pick electric tugs covered here when properly spec’d for the aircraft. Their electric motor drive tech has proven that the market has grown from the first electric Lektro, which arguably still sets a standard in pro ground ops. Big budget? A reliable workhorse, you can still get a 36-volt APU-equipped Lektro model 8300 tractor tug, new or refurbished.
We’ll look at them and other used and homebuilt tug options in our extended digital coverage at Aviation Consumer.
