Time for glue! I first glued the feet onto the base, because their positioning was the most important. Then I dry-fit the electronics six or seven times to make sure it all worked, checked the connections again (placing the LED against the wires). I glued the top piece of cork to the two pieces of cork on the front and back, as well as the top and bottom of the switch to the top cork and the base. These were the second most important parts. Not as much holding and stability as I’d like, but it’ll improve as we go.
I let that sit for a few minutes, then started filling. I pulled apart small pieces of cork and glued them into place where ever I could see into the insides. When this is all dry in the morning I’ll use oxid paste to fill all of the remaining gaps, but it works best if you don’t have to fill more than a few millimeters of hole.
Here’s a photo of where the LED will end up inside the torso. I’ve left the wires long for now, but will obviously be cutting them down to fit the light in.
Here’s what the underside looks like. You can see the switch on the right.
When I’m completely done, I’m going to fill some of the bottom with white glue to keep the battery holders in place, but for now they are snug-fit against all of the cork on top.
And here’s the next morning, with all those gaps filled.
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