I made mine with servo extension wire (probably 20 GA) and 18 GA wire for the power connections.
My runs were all under 20 feet. I know many have been using cat5 cable. That should be fine for short runs like mine. I know Joel has had someone do tests on how much signal loss there is in cat5 for various lengths. Perhaps he will chime in here with the results.
The upshot is that even though people have reported very long runs with cat5, there is considerable signal loss which could cause delays making your routines get out of sync with the audio file.
As far as the balance issues, I didn't have any. I ran my cable right up the neck and wire-tied it to the lower portion of the center rod. From there it went to all the servos from the inside.
I have seen pics of Capt. Jack's with the cat5 plug at the rear of the skull. I don't believe he has had any issues with balance, but I don't know. Maybe he will chime in as well.
I know that the servos are powerful enough to overcome a small issue like that. The problem would be when you shut off the power to all the servos, does the wire at the back pull the heads down causing them all to look up to the sky?
I don't know the answer to that either, but the Capt. might.
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