Ive used El before but in very small projects and always on something somewhat stationary. Add to the confusion and problems of not just wearable electronics but stretchy fabric that you intend to be very active in over a consistently long period of time. The intelligent short attention span person would smartly step away.. Uhmm, maybe run away from such a task. At least you would if everything had to be done by hand and you had zero helper hands. Somehow in my alternate reality state (think, Steve Jobs) I could only envision how super awesome it would be and what kind of reception it would get from others if I could pull it off.
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Picture on right better explains my method. Best part is it not only can account for the stretch of the fabric without putting strain on the delicate El Wire but as segments break I can just cut it out and re-insert a new piece without having to sew :) YAY because my fingers are trashed from all the needle threading and trying to strip and solder all those dam angel hair connectors around the copper wire.
Just the top of shirt took about 22 hours of labor and thankfully the pants will be so so much easier as they have only 1/8 of the connections. To help keep the wires in place a bit I just used a dab of hot glue for a spot-weld, works GREAT. Though most of the costume is still yet to be finished (and I only have about six hours to do it) I consider the short to be by far the most difficulty and pain staking, but it came out so well I'm confident the rest will come together with ease.. even if I just have to slap it all together with safety pins.
I have gone through running motions with wire attached and did have to make a change to where the joints are. For those areas I used 26gauge stranded wire for it's very nice flexibility and to prevent any "breaks" in the phosphor coating. I'm pretty confident everything will hold up relatively well and best case scenario is I'll try to wear this for 55 or more of my 100 consecutive miles being run. I'll get some video posted to better show the "Tron" aspects my self proclaimed "Dirt Nap Gaucho" costume, but here's a couple pics with lights on and off. BTW - get it.. Dirt Nap as in Dead, as in Muertos. Gaucho because I should have some hand sewn accoutrement's to depict the old style of Spanish Cowboy.
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