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Walt,

I'd be thinking about attaching the heat-shrink covered bundle of connector pins solidly in an adel clamp one side or the other of the penetration between the spar and the aileron, so only the loop of wires is exposed in the open area between them.  I would put a double layer of heat shrink on the exposed wire loop and capture both ends of the heatshrunk area as well, also in adel clamps or with wire ties attached to ClikBond or similar standoffs, assuring in the process that there are no angular bends, only smoothly flowing curves from one area to the other.  I'd make the two layers of heat shrink different colors, the outside black, the inside red, for example, so any chafing would be instantly visible during routine preflights when the inner color shows through.  I'm sure if you used high quality stranded wire that the very thin strands that make up the total combined conductor will slide adequately along themselves given the support they'd receive from the heatshrink and the smooth path you'd provided for them.  Just a couple thoughts......

  <Marv>

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