Robbie,
The star cloth isn't fragile at all, since it uses plastic fibre optics which can be bent and flexed without the risk of breaking or getting damaged.
There is no power or wires travelling through the actual cloth and so no risk of fire and it is therefore 100% safe. Since the material used is from a stage and costume supplier it is fire retardant in any case, although the risk from self combustion from the fibres alone is nil. The colour changer itself has a motorised colour wheel, so the light actually changes colour!.
There are 100 fibres within the cloth, and the ends of each fibre are simply pushed through a random pin hole in the fabric, then glued in place with a hot glue gun with the excess fibre trimmed flush with the cloth, which in use gives a very intense spot of light. The fibres are then bunched behind the cloth in looms, and all emerge neatly from a corner where they connect to the light box. The loom of 100 fibres are cable tied and then heatshrink is carefully (to avoid melting the fibres) shrunk over them for protection.
I had another identical piece of cloth neatly sewn over the back of the front cloth which sandwiched the fibres, and acts to protect & hide them. The finished project works 100% and looks very effective. After use, the cloth folds neatly, and is stored inside a gym bag along with the colourchanger.
Probably the hardest bit of a custom starcloth manufacture is the patience and time needed to do it. I spread the project over 3 or 4 weekends and all in all it probably took around 7 hours. If you had somebody to help you, then you would probably complete it all in one weekend.
The trick is to work on one fibre at a time, lay the cloth out flat on a large pasting table or similar, and then position one fibre, cut it down to size - allowing a little bit extra, push it through a pin hole, glue it, and then trim down the excess which protudes through the front of the cloth. Then move onto the next fibre and so on. Pretty soon you have a loom of fibres which can be bunched into small groups and then glued to the back of the cloth, to the corner where they all emerge. The result is rather like a roadmap of a motorway with lots of roads branching off it.
The whole thing cost me well under £200, which included the purchase of the Glue Gun - which does happen to come in handy for Jobs around the house, and sticking down ripped vinyl on speaker cabs!

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