Re: Star Lord w/ lights and sound - hair and blaster progress
Okay!
I took a bit of time off to attend to some things I had to do - a bit of healthcare related to my back, and also candidly a bit of Skyward Sword, since I ended up winning it on an eBay auction for cheap last week.

Now I'm gearing back up to finish some things, including the Infinity Orb run I've been planning, which I just put an interest thread up for in the classifieds section.
Finishing the Electromagnet Base jumped to the top of my to-do list when my own finished Infinity Orb very nearly rolled off the shelf I left it on. I revised my hinge design a bit, and exploded it out into parts for easy 3d printing, as seen below:
I'm going to be printing these in separate parts and then making a couple molds. My plan is to have each hinged flap be a single, solid cast piece when I'm done, and the middle will sandwich together in a two-piece assembly to close over the hinge pins on the flaps. It should fold up just fine. The only thing I'm debating is the actual scale of the electromagnet itself. I'm trying to eyeball it close to the scale it looks in the movie, and I'm 3d printing the middle bit right now to size it up. As soon as I'm sure I have the scale right, I'll be adding the files to the OP for download, and throwing it up on Shapeways as well.
Also: I got a PM asking about how to glue PLA prints, and I figured I'd answer the question in-thread in case anyone else was having a similar issue. My final helmet revision was assembled using a combination of hot glue, cyanoacrylate superglue, and JB Weld epoxy. The method's pretty straightforward - I apply superglue to both halves of the pieces being joined to start with. The superglue I use is
basically this stuff, but my local hobby store has slapped their own brand on it. I love this glue. There's a very thin version that flows like water and has a blue label, but this stuff will set in about 10 seconds and won't run.
Once I have both parts glued along their seams, I press them together and apply hot glue to the back. The hot glue, in the case of the helmet, was used to allow the helmet a bit of flexibility while still attaching the parts, since I wasn't sure if it was going to fit my head. It also helps hold the pieces steady while the cyanoacrylate dries, which is very useful. Once the hot glue has set and the CA has had a chance to dry, I hit it with
JB Weld Original. I squeeze out equal amounts onto a scrap piece of cardboard or something equally disposable, and mix with a tongue depressor for a few minutes. Then I use that same tongue depressor to paste the JB Weld over the hot glue and across the seam. The Original version of JB Weld takes 4-6 hours to set and about 24 hours to be at its' strongest. There is a 'Kwik' version that works in about a quarter of the time but doesn't end up quite as strong. Your mileage may vary, but I've had trouble getting the Kwik to stick as well to the PLA.
This is what the helmet looks like after all of the above:
It's very solid, and I could probably sit on it without any problems. Not that I would, but the point is it's wearable for cosplay if you wanted to just go with a straight 3d printed helmet. I'm going to try and make resin copies once I'm done, though, just to learn how!