Laminating the Skywalker X8 With 22g Fibreglass Cloth – What I Learned & Would I Do It Again?
For this stage of the Project-X8 build, I finally committed to fully laminating the Skywalker X8 airframe using 22g lightweight fibreglass cloth. The goal was simple: increase durability, stiffness and surface strength while keeping the weight gain as low as possible. After a long weekend, sticky hands and a workshop that smelled like resin for days, the wings and fuselage are now fully wrapped—so here’s a breakdown of exactly how I did it, where I added more layers, and what I’ll change next time.
Why 22g Cloth?
I chose 22g glass mainly for:
- Strength without a huge weight penalty
- Ability to drape over complex shapes
- Minimal sanding compared to heavier cloth
- Perfect for foam planes when you don’t want to add 300–600g
It also layers extremely well—great for reinforcing high-stress areas.
Surface Prep
I started with the usual:
- Light sanding
- Dust removal
- Foam cleaned with isopropyl
But here’s the truth: 22g cloth shows everything. Any pits, tiny dents or rough patches telegraph straight through once the resin cures. It doesn’t self-level like a thick epoxy layup—it behaves more like a skin that takes on every contour beneath it.
Lesson learned: next time I’ll spend twice as long prepping the foam before the cloth goes on.
The Lamination Process
- Cloth laid dry over each wing and fuselage section. I let it sit naturally so it conformed without stretching.
- Applied polyurethane (or chosen resin) with a soft foam brush. The resin soaks through 22g cloth instantly, making it easy to work with.
- Worked from the centre outwards, keeping bubbles to an absolute minimum.
- Trimmed the excess once tacky.
Total lamination time:
Wings – around 2 hours each
Fuselage – 2–3 hours depending on curve complexity
Where I Added More Layers
Some areas needed double or even triple layers:
✔ Wing Leading Edges
This is where the X8 takes the most abuse—landings, scraping, general handling.
✔ Motor Mount Area
Especially with VTOL and extra vibration, reinforcing the rear was essential.
✔ Wingtips
These always get knocked about, so an extra strip of 22g added a nice rigid feel.
✔ Underside Belly Section
This area drags on landings. A second layer helps massively.
Final Weight Increase
Adding 22g cloth plus resin added only a small amount of weight, especially compared to 80–100g cloth. The stiffness and strength gains far outweigh the grams added.
Would I Do It Again?
100% yes.
The X8 feels solid—more like a composite wing than an EPO foam one. Handling it now just feels premium, and it should last far longer with less hangar rash.
What I’d Do Differently Next Time
If I was to laminate another X8 (and let’s be honest… I will), I’d make one major change:
🔥 Better surface prep.
Because this isn’t thick epoxy laminating, the skin doesn’t hide imperfections. It highlights them. Every tiny pit in the foam shows through once the cloth cures.
Next time I’ll:
- Fill dents with lightweight filler
- Sand to a finer grit
- Smooth out factory mould marks
- Bring the surface closer to “paint ready” before even touching cloth
That prep work would give the final finish a much more uniform, professional look.
Final Thoughts
The 22g glass cloth has transformed the X8—stronger, stiffer and far more durable while barely adding weight. It’s a messy job at times, but absolutely worth the effort. If you’re looking to level up your EPO builds, this is one modification I’d definitely recommend.