As far as questions go, there's a lot of this stuff that I might not think needs explaining or I might be unclear about what I'm doing. If I need to clarify something, please feel free to ask all you want.
There is no soldering for EL tape. If you add heat to it, you'll burn holes through it. Instead, you basically have to clamp the wires onto the conductors and then glue them in place. Then seal the whole thing up with tape.
I looked at your RIG progress pics. Looks like you're off to a good start. If you decide you'd like to spend money on your helmet instead of building one completely from scratch, I'm willing to sell raw casts from my mold.