homebrew dlg, HELIOS src - RC Groups
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Dec 21, 2010, 12:07 PM
1 revolution and throw!

homebrew dlg, HELIOS src

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
Last edited by krikkens; Nov 10, 2011 at 02:31 PM. Reason: zone v2 airfoil now
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Dec 21, 2010, 12:19 PM
a.k.a. Bob Parks
Karl Zeiss Blue, should be accurate!
Dec 21, 2010, 04:35 PM
1 revolution and throw!

rds system


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...

Dec 21, 2010, 06:59 PM
Registered User
pyrsly's Avatar
Sweet! Now You have no excuse, You have to mill a fuse mould for Me!
Dec 21, 2010, 07:08 PM
ThomasLee's Avatar
oh dang, I think you have half the people here drooling!
How much did it cost for that setup?
Dec 22, 2010, 01:35 AM
1 revolution and throw!

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


Dec 23, 2010, 12:09 AM
ThomasLee's Avatar
Thanks for the link, looking forward to seeing some build progress! *drool*
Dec 23, 2010, 04:40 PM
1 revolution and throw!


hi ,

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

Dec 28, 2010, 06:42 AM
1 revolution and throw!

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...
Dec 28, 2010, 12:35 PM
ThomasLee's Avatar
looks really good, how long does it take to mill a set of wing cores?
Dec 28, 2010, 01:41 PM
1 revolution and throw!

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 .

Dec 28, 2010, 04:45 PM
1 revolution and throw!

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

Dec 28, 2010, 05:52 PM
ThomasLee's Avatar
maybe a carbon rod spar will be easier since you can mill out the slots on the cnc?
Dec 28, 2010, 06:00 PM
Team Swallow
Jonas M.'s Avatar

You're the man!

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