Building a Skywalker X8 for long-range FPV and autonomous flight is basically a balancing act between strength, serviceability, and weight. The EPO foam fuselage is roomy and forgiving, but mounting electronics, batteries, and accessories usually means hacking away at the foam and hot-gluing things in permanently.
That works… until you want to change something. Then you’re left with a chewed-up fuselage and regret.
So I decided to design my own 3D printed modular plate system, canopy hinge, and lock. Stronger, lighter, and much easier to maintain.
Moving Away From Heavy Plates
My first attempt was what I call the “pic wall” design: 10 mm holes drilled at 45° spacing to make a honeycomb-like grid. It worked, but each plate weighed around 150 g — far too heavy for a build where every gram matters.
Back to the CAD.
This time I scaled the pattern up to 50 mm hexagons. Same modular idea, but with a fraction of the weight. It gave me the strength and flexibility I wanted without turning the fuselage into a flying brick.
Modular Mounting Inside the Fuselage
Each hexagon slot can accept a custom 3D printed insert plate. That means I can mount:
- VTX
- ELRS receiver
- GPS
- RX5808 diversity modules
- Even a parachute release system
…without cutting into the foam again.
Need to upgrade or change hardware later? Just print a new insert, drop it in, and go. It makes the X8 far more serviceable and future-proof than a stock build.
Printing Settings That Worked
I went with PETG for all parts. It’s tough, flexible enough to handle repeated use, and less brittle than PLA.
- Walls: 5 perimeters (so the inserts survive multiple swaps)
- Top/Bottom layers: 3 each
- Infill: 15% (gyroid)
- Layer height: 0.28 mm for speed & strength
- Cooling: 40–50% fan for good bonding without sag
The results? Strong, reliable prints with almost zero warping. They snap into the fuselage with a nice, confident fit.
Custom Canopy Hinge and Lock
Magnets and tape work in a pinch, but I wanted something more professional. So I designed a 3D printed hinge + latch system:
- Hinge = printed knuckle + carbon pin
- Latch = quick-release clip (hand operated)
- Bonus: It can be adapted to a servo later if I want to integrate a parachute system
Now the canopy opens and locks securely — no fussing with tape, and no mid-flight surprises.
Reinforcing the Fuselage
The stock fuselage uses 10 mm carbon rods. Good, but not good enough for heavier loads. I upgraded to 12 mm carbon tubes, cut flush with the fuselage for a clean finish.
The wings still use 10 mm rods, sanded for a snug fit at the transition point. The result is a stiffer, cleaner fuselage structure without a major weight penalty.
Results
The combination of lighter modular plates, a smarter canopy system, and stronger fuselage reinforcement has transformed the X8:
- Lighter overall structure
- Far more modular and serviceable
- Stronger fuselage core
- Ready for future upgrades (like a parachute release or more sensors)
And since everything’s printed in Sunlu PETG, it’s durable enough to survive repeated swaps in the field without cracking.
This isn’t just about making the X8 tougher — it’s about extending its lifespan and flexibility. With this system, the Skywalker X8 can evolve alongside the tech we put inside it.
