Well I ended up using all my Nichrome wire last weekend so I had to order more and due to time constraints I do not think this project will be any where near ready for the Hackaday Challenge this year.
My current go forward is to complete a Proof-of-concept robot forearm and hand of limited motion all powered by groupings of twisted nylon actuators and using sweat like evaporative cooling . I was unable to find a suitable waterproofing yet but have ordered Silicon conformal Coating which should work along with my order of additional 36 gauge nichrome wire.
We will see how that goes next week!
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