Thanks for the replies, guys.
IC2, on the door jamb contacts I have heard bad feedback about their reliability and have seen some abandoned in place with wires added so I'm not sure I trust using them. I've seen the plastic bellows type and they look like a good possibility for the door. Your approach to fanning out wires is probably where I am, maybe between a couple of layers of insulation.

Mike, that hinge mod is sweet - lots of work, but really a trick idea.

Don, your suggestion of a tube following the hinge line is a great idea, too. I will also check out Grey Stuff this morning.