After trying it on several Velcro dots with some good early success, it was determined that the contact cement would work adequately (although a still-better solution could be sought) but that it is required for it to cure overnight to reach full strength. After following the directions of applying to both surfaces and then allowing it to slightly cure until just tacky before pressing the surfaces together, the bond was similar to the tape by itself. It was later found that after the parts had sit for overnight or longer that the glue was indeed sufficiently strong and flexible as long as one is careful upon removal to try to grab the Velcro itself and not pull on the mask to remove it.
The final result of attachment (Figure 2-3) was quite different from the raw framework and slack mask from which it was made.
Each servo that was already on the “skull” was tested to make sure that they all functioned properly. Once the bad servos were found and replaced, they were again tested for full motion control once the mask was attached. This last was done to find out the range of motion that the mask would allow, without either tearing or causing the Velcro fasteners to loosen.
The previous controller which had been mounted on the back of the shoulder area did not support synchronized sound nor did it have wide software support. The controller was replaced with two identical Mini SSC II controllers as outlined in the section "Servo Controllers". The two controllers were mounted into the same position on the back of the shoulder area.
As this robot head had been used on other projects, there were many unknowns as to its condition. The servo wires had been lengthened and replaced with solid conductor wires - each terminated individually with a female connector. The use of solid wire was problematic in that solid wire is less flexible and the large number of conductors made a significant impediment to head and neck motion which also flexed the solid wires back and forth. To both ease the motion restriction and prevent possible breakage of the solid-core wire (which breaks much more easily than the more flexible stranded-core wire), it was decided to replace all solid core wire with stranded wire.