Nathaniel,
Thanks for taking the time to post the detailed narrative on your Trio AP install! It sounds like you encountered many similar challenges to my own. I noted a couple of topics where I would like to offer alternatives. DISCLAIMER: Sorry, I have to say it; the reader assumes complete and total responsibility for the use of the following information, and any consequences that result.
1)
Also you're gonna want an inspection hole in the outboard flap well area outboard of the last flap track, outboard as far as possible, to install the one screw into the aileron servo mount that is in the flap well area behind the false spar. We managed without but it was over 4 hours to install that one screw - not kidding.
PLEASE DON"T cut any more inspection holes in your airplane than absolutely necessary! As you mentioned, only 2 nutplates are installed on the roll servo bracket. So, install 1, but leave the top forward nutplate uninstalled. With your flaps down, install the three screws into the three nutplates you have open access to. Now, using a long drill bit, drill the fourth hole for the bracket, from the outboard side, operating through the 6 inch inspection hole (Actually, I think I used a power screw driver, turning a hex adapted drill bit). Next, get a #8 hex head machine screw of the same dimensions as the fourth mounting screw. tightly coil some .031 safety wire around the screw, just under the hex head. Reaching into the wing, insert the bolt pointing outboard toward you. The safety wire is to retrieve the bolt if dropped, and to hold it during installation. Once you have the bolt through the hole, hold the safety wire, and install a flat washer and locking nut on it. Now, pull the safety wire to uncoil it from the bolt, and remove. Finally, using a small "ignition wrench to hold the hex head, tighten with a 1/4" drive ratchet, long extension, and a universal (wobbly) socket. This combination works, and should cut down on the time required by an appreciable amount.
2)
The aileron wiring I ran inside heat shrink tubing (the kind with some adhesive on the inside) and that added some rigidity to the wiring and some weather protection since it had to run in the flap well area with the flap/aileron cables. You can get a 50' roll of the stuff on Amazon. It was literally pushing rope to feed it down the heat shrink tubing, took about and hour.
Tip for pushing wires down a length of heat-shrink, or any other type of tubing; run a small, single conductor fish wire first. Then strip a generous length of insulation and attach to the wire(s) to be pulled through. Attaching to the wire(s) to be pulled can vary. Soldering is preferred as it greatly lessens the possibility of the fish pulling away from the wire(s) being pulled. You can even "lube" the wires just behind the joint with dish soap if you want, then gently pull your wires through. If you can't reach both ends yourself, a helper is a necessity.
For this specific project, a great routing for the roll servo wire is to go forward from your 6" inspection hole, through lightening holes in the spars, then a gentle left (or inboard) turn to the existing set of holes in the nose ribs through which the nav light wiring passes. To protect from chafing where the wire passes through the lightning holes, one can use an approximate 4 ft piece of 1/4" OD Poly-Flo Polyethylene tubing as a conduit. Since there is lots of extra servo wire, here's a suggested method:
1) Route the roll servo wire up the right front door post, and out into the wing route area.
2) Remove the inspection panel in front of the strut to wing spar junction.
3) Remove the right wing tip, or at least the right nav light.
4) Disconnect the wire from the nav light, and attach at least 10 ft of "fish" wire to the nav light wire.
5) Pull about half of the nav light wire back into the wing route area.
6) Tightly tape the roll servo wire to the nav light wire.
7) Gently pull the nav light wire back toward the right wing tip. It really helps to have an assistant during this.
8) When the two wires appear in the inspection opening in #2 above, remove the tape to separate the wires.
9) Pull the extra roll servo wire out of the inspection hole, and pull any remaining nav light wire back out to the wing tip and secure there.
10) Using a stiff wire, (12 or 10 gauge solid copper house wiring works) or other suitable item, insert it through the roll servo inspection hole (the one that was increased to 6" diameter). Work it forward, perpendicular to the wing spars, until it emerges into the leading edge of the wing, outboard of the inspection opening in #2 above.
11) Hook this wire with a loop or hook and while a helper keeps feeding it forward from the 6" opening, pull it inboard toward the 4" opening (#2 above).
12) Tape the roll servo wire to this stiff wire. Push and pull the stiff wire back to the 6" opening until you have all the extra wire fed through.
13) Now we need to protect the servo wire with a length of Poly-Flo Polyethylene as a conduit back through the wing. Since the servo wire has 4 sockets already crimped on, this will be a bit of a challenge, but it can be done rather easily.
14) Carefully slice and remove the heat shrink at the terminal end of the servo wire. Do NOT hurt the wires or insulation!
15) Use a length of 22 gauge as a fish wire. Insert it through the 4 ft length of 1/4" Poly-Flo Polyethylene tubing.
16) Strip at least 1.5" of insulation from the end of the fish wire.
17) Set up your servo wire for pulling through the Poly-Flo Polyethylene tubing in the manner depicted below. The four sockets will NOT pass through side by side. A staggered configuration works well. Recalling the knot craft you learned as a Scout, tie the bare conductor of the fish wire to the servo wire using a clove hitch knot. This knot is exceedingly useful for this type of application; it tightens as pulled, and causes only a slight increase in diameter to the wires being pulled.
FishWirePic.jpg
18) After pulling the servo wire through to the tubing, slide the tubing to the front of the wing and inboard to where the wires emerge from the hole in the nose-rib. Secure the Poly-Flo Polyethylene tube with wire ties, and trim its length if desired, again using extreme care to not damage the wire inside.
19) Remove the fish wire and straighten the four conductors and sockets.
20) Replace the piece of heat shrink over the terminal end of the servo wire in the same manner, length and color as the one removed in #14.
21) Reconnect nav light and reinstall. Test for proper operation.
22) Proceed with installing the servo wires into the Trio provided DB9 connector, and the balance of their installation procedure.
This sounded complicated to me as I proof read it. However, it really works, simplifies the routing of this wire, and keeps it completely clear of moving aileron and flap cables. Hope this helps!
Karl