Randy, Wire comes in a huge variety of flexibility. There are special wires that can be flexed millions of times in a relatively tight radius. Other types of industry use such wires, like in my field, which is elevators. We use special flexible cables to power the elevator cab, that often lasts the life of the building, all the while constantly flexing. Your Viper will be in the Smithsonian, before some of these types of wires wear out! This type of wire is much more expensive than what is used in automobiles, because auto manufacturers use about the cheapest wire they can, as the cost savings mutilplied over millions of units is substantial. That is why you will never see special flexible general wiring in most autos. Most of the time, the grade they use is adequate, only in this case of the Viper, the spec and expected use of the wiring was exceeded.
Although the connection between the car body and the door is poorly designed, (as you so aptly stated), imo, replacing with super flexible wiring is the cheapest alternative. Yes, changing the the boot arrangement would mitigate the bending effect, but it is still a lot more work than just changing the wires themselves. Randy, Who knows!, maybe I'll end up doing exactly what you describe. But I'll wait and see how long it takes the super-flex stuff to break. Next time I get in there, will be the last time!
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