Thanks to everyone for the feedback and support. I'm glad this thing has been a hit within the community.
Matt, I spend about 10 hours a week working on it, give or take. I seem to be able to turn out a level a month so far, but I actually started the project in June, and spent a solid month planning things out level by level so that everything would fit just right. A lot of the work time now is spent on designing the decals, since this is my first opportunity at photoshop-type applications. The plan has always been to finish by December, and that looks like it'll happen.
I'm still looking for something to use as those wall sensors, I've got plenty of room to stick 'em, but I love those little cannons...
The console is built from a foamcore skeleton covered with black posterboard skin. Basically, the leg pieces are two pieces of foamcore joined face-to-face, the back one slightly taller than the front. A third wedge-shaped piece is placed on top at the angle made by the different heights. Then the posterboard covers the joints, with stickers and scavenged car model pieces to complete the look.
The next level to come will be the Docking Level, featuring the Command Office (above Leia's Cell) with an opening/closing door and rotating computer screens. The elevators continue up into the docking level also to give the illusion of a straight ride (though they are non-functional). A curving hallway joins the two sides, with the Docking Bay Doors (and a large decal of the Falcon in Hanar 2037) in the rear center.
I don't think I could build another Death Star, though. This one was all about seeing my wishlist of rooms and features come to life, someone else would want other things and <poof> the magic would be gone for me.
(Of course, if enough
money were offered, I'd stop being an idealist real quick...)