I was able to get a bunch done today. First, I got all the body lights done. For one of the cut outs I split the pipe in two with some foam board and added one blinking red and one steady yellow light. As far as the lights go, I didn't stick with screen accuracy, I just went with what LEDs I had on hand.
I added lights to all the cut outs. In total, I used about 25.
I bought this audio box online and downloaded some BB-8 sounds to it. It'll hold about 5 minutes but I think I only put about 3 minutes of audio on it. I disassembled the box so I could mount the speaker closer to some slits that I cut out on the back of his head. I also rewired a new momentary button; push to start / push to stop.
Here's a test of the audio.
I mounted the entire unit in the head. I'm still able to attach the USB cord and change the batteries.
And here he is with the lights and sounds.
Now that the audio and lights are done, I'm going to rework the weathering, add the eye cover and antennas, then it's about done.