So the tubing mistake, no biggie. Easily fixed. What isn't is the relay issue i've been having. After a volley of emails and a phone call, I think we came up with a solution.

The problem is the relay would short out due to an influx of power (a power spike) causing the board to work. The work around is to put a capacitor between the neutral and hot cord starting at the relay board This appeared to do the trick so I rush ordered 20 higher, better quality (and properly rated) capacitors to Chicago.

This means I have to create 24 Y connectors (done), create 24 daughter boards with literally no wire to the relay board (or just do a splice with some heat shrink and solder), create the 24 extra wires (figure 4 feet each?) for the extra wire run.

This is still going in blind to a degree since I only have 1 spare motor and just because my few tests didn't cause it to happen doesn't mean the problem still doesn't exist. I think the relay boards will have to be swapped out due to this.

Wheels up in 44 hours. Plenty of time, right?