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Jan 28, 2010, 02:49 AM
Thermal Wrangler
DrFragnasty's Avatar
Thread OP

Scratch-building a Nexor Pro

The Nexor is the product of the fertile minds of Bruce Nye, Steve Boag, Marcus Stent, Tim Lennon and occasional elbow grease from me.

The Nexor is based on Supra foils but using a different planform and different everything else.

It's flown for a year and it works well but can always be improved upon. The molds worked well, the lay-ups, templates and procedures worked well so the effort to produce a molded glider is greatly reduced. Reduced enough for me to have a go!

First-up the balsa skins are 1mm medium soft. The joiner boxes and joiners are done. The balsa shear webs are cut and the sub-spars done.

Chris Adams
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Jan 28, 2010, 02:52 PM
Thermal Wrangler
DrFragnasty's Avatar
Thread OP

Poraver & MDF

The mold filler is Poraver. Cheap. Lightweight. Works. We'll use it again.

MDF is "medium density fibreboard":

Not sure if you can get the exact product in the US. It's a high-density wood product (Radiata Pine is used in Australia). Fibres are mashed-up then re-combined with resin and wax at high temps/pressure.

Jan 28, 2010, 04:40 PM
Deniable plausibility
Shedofdread's Avatar

Watchin' with interest.


PS Did you give 'she who must be obeyed' the poraver bowl back?
Jan 28, 2010, 05:32 PM
working to the closest cm
jirvin_4505's Avatar

Mixing poraver

Hi Chris great to see the SEAT team posting on Rcgroups.

Following with interest.

My shedbuddy Shane used Poraver to make a fuz mold - awesome stuff!

He used a battery drill to drive a paint mixer and reported it was a 'piece of cake' to mix...

cheers jeff
Jan 28, 2010, 06:10 PM
Just fly it!
wyowindworks's Avatar
Nice work guys.

I always use glass bowls from the kitchen rather than the metal ones. That way when the wife is looking for it I can just say that I broke it while doing the dishes .

Jan 28, 2010, 06:46 PM
Thermal Wrangler
DrFragnasty's Avatar
Thread OP
Tah for the mixer tip Jeff. Dunno about the bowl Shed...that was a matter for Bruce and his SWMBO. Adam; cunning solution!

Jan 28, 2010, 09:31 PM
Retired USAF
cynjon's Avatar
You do nice work Chris...wish I had the skills/time/money/workshop to do stuff like that. Keep the build threads coming!
Jan 28, 2010, 10:13 PM
Thermal Wrangler
DrFragnasty's Avatar
Thread OP
I can't take much credit for the accuracy/ fidelity of the process Jon.

Bruce & Steve are both gifted in that regard. I just slop the resin in and hope for the best ;0)
Jan 29, 2010, 02:02 AM
Hi Guys,

Just to add a bit more info to the thread, we are also working on a modular fuz design. We are only in the early stages at the moment. Tailplanes and F3B pod have been modelled up in the CAD program. F3J pod for the Nexor is next. No CNC plugs/moulds have been produced yet.

We want a fuz system that allows us more flexibility when coming up with new models/concepts and parts/moulds that are easy and quick to produce or modify. We don't want to have to make new fuz moulds every time we want to produce a different model.

It is basically a pod and boom system but with the all carbon boom extending forward of the wing seat. The pod (different for F3B/J) then goes in front. Size and wetted area has been kept to a minimum but not to the extent where structural strength is compromised. Tail groups (x-tail, plug on v-tai) will essentially be the same as the Baudis Trinity concept. A small wing seat mould will be produced to sit on the top of the boom.

New wing designs will only require a new wing seat to be produced to allow for different airfoils, wing chord etc. The wing seat and tail groups can be easily moved to adjust moments as the boom mandrel is longer than necessary.

It probably won't be as sexy as some of the commercial (or home grown) fuz's, but the ease of manufacture and flexibility of this system should make it worthwhile. The CNC machined 2-piece steel mandrel is finished and can be viewed at

Chris can post pics when we have made further progress.


Jan 29, 2010, 03:21 AM
Registered User
Jan 29, 2010, 03:40 AM
Thermal Wrangler
DrFragnasty's Avatar
Thread OP


Apologies for the timewarp photo-sequence; here's the Nexor in it's element at Milang F3J (Sth. Australia) last yr.

Maiden flight with the glue still drying ;0)

Last edited by DrFragnasty; Jan 29, 2010 at 03:55 AM.
Jan 29, 2010, 07:20 PM
Everything’s A Compromise
Larrikin's Avatar
Originally Posted by DrFragnasty
Apologies for the timewarp photo-sequence; here's the Nexor in it's element at Milang F3J (Sth. Australia) last yr.

Maiden flight with the glue still drying ;0)

Thanks for posting all the photos. We all love photos "Maiden flight with the glue still drying " I wouldn't mind betting that it'll be the same for Evan's Sniper at Milang too.

Jan 30, 2010, 04:41 AM
Thermal Wrangler
DrFragnasty's Avatar
Thread OP
Tah David, hope your Sniper claims a few scalps at Milang ;0)


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