Builder answers

Frequently asked questions.

Answers from the OpenHornet FAQ, organized for builders working through releases, tooling, fabrication, wiring, displays, software, and licensing.

Where can I find the OpenHornet release files?

Start on the OpenHornet Start Here page. The current latest hardware release is available here.

Where are the drawings, manufacturing files, and parts lists?

The drawings, manufacturing files, parts lists, and related build documents are all available from the hardware build package. Use Start Here to get the latest package.

What version of DCS-BIOS does OpenHornet use?

OpenHornet supports the DCS-Skunkworks, formerly DCSFlightPanels, branch of DCS-BIOS: DCS-Skunkworks DCS-BIOS fork.

Where is the OpenHornet software for the ABSIS PCBs available from?

Software is tracked separately in the OpenHornet-Software GitHub repository.

What tools do I need?

Minimum tooling requirements are listed on the Start Here page. The current guidance assumes a capable shop with CNC routing, laser cutting or engraving, 3D printing, electronics assembly, and careful measuring.

What phases are in the build?

The build mainly consists of painting, structure, electronics, and software.

Fabrication

You will fabricate MDF, acrylic, and 3D printed parts, including the upper instrument panel, lower instrument panel, left console, right console, center tub, seat, flight stick, and throttle. After fabrication, you will paint and assemble the parts.

Electronics

Electronics work includes wiring, backlighting, panels, screens, PCBs, Arduinos, and gauges.

Software

Software work includes Arduino code or sketches and DCS-BIOS setup.

What sound system should I use for my sim?

OpenHornet does not prescribe a specific surround sound system. Builders should choose whatever is locally available, fits their budget, and meets their individual cockpit requirements.

Can I make flat parts by hand instead of with a CNC?

OpenHornet assumes builders are using a CNC router, so the drawings do not fully detail every CNC-cut or flat part for hand fabrication. Several builders have successfully built the structure and associated parts by hand using common woodworking techniques. You will need to lay out the SVGs from the build package, print them at 1:1 scale, and use those printouts as fabrication templates.

What metric MDF sizes can be substituted for the specified imperial ones?

OpenHornet is designed to use 0.75 inch, 0.50 inch, and 0.25 inch MDF. Some metric builders have successfully substituted 19 mm, 12 mm, and 6 mm MDF with a minimum of tweaks to printed parts.

How much MDF do I need to build the OpenHornet structure?

Approximately four 4 x 8 foot sheets of 0.75 inch MDF, one sheet of 0.50 inch MDF, and one sheet of 0.25 inch MDF. OpenHornet is designed around MDF; material substitutions are at the builder's own risk.

I have the build package, but I really need the Fusion 360 models?

That is fine. Use the guidance on the Start Here page for model access and download paths. Treat raw models and working files as reference unless the release package says otherwise.

How does an IO board/PCB work and how do I attach stuff?

ABSIS, the Arduino Based Simulator Interface System, is the OpenHornet electronics layer. It consists of PCBs connected to Arduinos. You download or write the Arduino sketch, wire the PCB to the panel or component, and connect it into the system in accordance with the OH-INTERCONNECT drawing.

Is there a wiring walkthrough?

Yes. Reference the OH-INTERCONNECT drawing in the build package. You can download the build package from Start Here.

What specific wires do I need for which buttons and screens?

Follow the OH-INTERCONNECT drawing in the build package. The build package is available from Start Here.

Do I need connectors?

Yes. OpenHornet primarily uses DuPont and Molex connectors, plus several others. Follow the OH-INTERCONNECT drawing in the build package.

Do I have to attach the connectors myself or are there pre-crimped wires?

Pre-crimped DuPont and Molex wires are available; builders often find them on eBay or AliExpress. Buying many pre-crimped wires can save time compared with crimping every wire yourself, though you will still want appropriate crimping tools for cases where custom wires are needed.

How do I make buttons work?

OpenHornet uses ABSIS. Obtain the correct PCBs by having them fabricated from the manufacturing files in the build package, purchasing them from an OpenHornet Authorized Vendor, or arranging a group buy in Discord. Once you have the PCBs, wire everything according to the OH-INTERCONNECT drawing.

How do I source electronics components?

OpenHornet generally sources electronics components from DigiKey and Mouser. If a component is not available from those two, try Octopart to search distributors. After that, plain old Google can help track down alternates or remaining stock.

How do I source hardware?

McMaster-Carr is the primary hardware source referenced by OpenHornet, mostly because McMaster part numbers are convenient and precise for design documentation. You do not have to buy every item directly from McMaster. Use the specified McMaster part number to identify the size, material, finish, and standard, then source equivalent hardware locally or from another supplier when that makes more sense. That can be much cheaper than buying a box of 100 screws when you only need 3.

What displays should I use for the internal displays?

OpenHornet specifies the screens required for DDI, AMPCD, IFEI, SARI, RWR, and other displays in the build package drawings. Download the build package from Start Here, then review the drawings for the assemblies that contain displays. Screen part numbers are listed in the parts lists.

How do I mount the internal displays?

Displays are installed using the relevant 3D printed mounting structures specified in their respective assemblies.

Why does the stick not have force feedback?

The decision was mainly based on how the real F/A-18C operates. The real aircraft does not have force feedback in the stick except for mechanical reversion FCS mode, which is extremely rarely used by DCS pilots. Adding active force feedback would increase cost and complexity without much practical benefit for most users.

The flight manual does describe AOA feedback and increased stick force with AOA. In the F/A-18C, stick input rate to the FCS decreases as AOA increases, so the pilot needs more stick travel for the same control surface deflection. More deflection requires more force, which creates the force increase described in the manual.

The OpenHornet stick is designed to replicate the real aircraft's range of motion, force gradients, breakout forces, and damping forces.

Do third-party panels fit?

The OpenHornet team has not tested third-party panels for compatibility, so there is no official yes or no. Several builders have tried third-party panels, and they generally do not fit without modification.

Can I sell OpenHornet parts, designs, or derivatives?

Not under the public noncommercial license alone. Selling parts, designs, or derivatives would violate the NonCommercial clause. Apply to become an OpenHornet Authorized Vendor before selling OpenHornet-based parts or assemblies.

Can I use my OpenHornet for commercial purposes?

Every commercial use case is different. Reach out through the Contact Us form with a detailed description of the use case you are envisioning.

Still stuck?

Ask with context and the community can move faster.

Include your release version, assembly, part number, photo or screenshot, and what you already tried.