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        Discussion homebrew dlg, HELIOS src

#1 krikkens Dec 21, 2010 12:07 PM

homebrew dlg, HELIOS src
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helios build thread:



this thread continues the "how to start for your first dlg design" one.

i started this new thread cause i can hardly say this bird is my first dlg anymore

i got a name for it and am the proud owner of a new cnc machine to build this plane.

first the name , HELIOS src, the src stands for solid rohacell core.

the tail feather's AND the wing will be cut out of a solid rohacell block .

the planform is almost exactly the zone v2 planform .

vertical :EDGE vertical 2.1 dmē
horizontal (hinged): HT22 2.1dmē
wing : zone v2 20.2 dmē

vertical can be placed on the outside , a vertical saddle is moulded onto the fuse , this makes the connection between horn and servo very easy
also it's easy to mount and alway's at the correct angle .
i can mount it the usual way to offcourse...

more to come...


here are some pic's/drawings

#2 krikkens Dec 21, 2010 12:15 PM

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cnc machine...

#3 bbbp Dec 21, 2010 12:19 PM

Karl Zeiss Blue, should be accurate!

#4 krikkens Dec 21, 2010 04:35 PM

rds system
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i put together my own rds system,the box is made out of bearing plate , reinforced with CF .

the alu coupler is filled with "liquid metal" ,2 component plastic that can resist 90°Celsius and is pressed on the servo gear while curing

the first one is a bit on the heavy side but very strong.
the metal wiper goes all the way into the coupler

9grams /set
it can loose about 2 grams i guess but i'm not sure i will change it , i like overkill on it and the weight is close to CG,so...


#5 pyrsly Dec 21, 2010 06:59 PM

Sweet! Now You have no excuse, You have to mill a fuse mould for Me! :D

#6 ThomasLee Dec 21, 2010 07:08 PM

oh dang, I think you have half the people here drooling!
How much did it cost for that setup?

#7 krikkens Dec 22, 2010 01:35 AM


i already had the software and drivers from a smaller cnc machine , the machine itself you can find here:



#8 ThomasLee Dec 23, 2010 12:09 AM

Thanks for the link, looking forward to seeing some build progress! *drool*

#9 krikkens Dec 23, 2010 04:40 PM

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hi ,

today i assembled my vacuumtable and i hope to cut a first wing core tommorow ...


#10 krikkens Dec 28, 2010 06:42 AM

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rohacell cores are almost done.

aileron, spar and wingmount holes are cut into the cores , the first one i'm gonna make is without rds , that will be machined too on future cores.
mould is waxed and painted .

i'm gonna use carbon tow for sparcap wich hopefully fit the cnc'ed slots well.
if the wing has no sufficient bending stiffnes i'll cut a thin slot all the way thru and glue a thin piece of hardwood in , this should do the job, no doubt.

here are some pictures , more to come...

#11 ThomasLee Dec 28, 2010 12:35 PM

looks really good, how long does it take to mill a set of wing cores?

#12 krikkens Dec 28, 2010 01:41 PM


this one about 5 hours , but i'll probably get an hour off.

stepover was 0.6 mm on the first half but 0.8-1mm should do fine .


#13 krikkens Dec 28, 2010 04:45 PM

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first wing is curing now.

maybe i need to do the spar system some other way, let's see the result tommorow.
i found it hard to position the way i did.
i layed down wet out cf tow on some marks i made in the mould
then pressed the core into the mould and layed the same amount of tow directly into the slot's on the other side off the core .

i also armoured the LE this way , as skin i used 50 gr glas , so i can see if everything is well positioned afterwards.

here are some pics


#14 ThomasLee Dec 28, 2010 05:52 PM

sweet :D
maybe a carbon rod spar will be easier since you can mill out the slots on the cnc?

#15 Jonas M. Dec 28, 2010 06:00 PM


You're the man!

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