1. Any rf/interference/other reason not to put 2 runs of the Sommer in a piece of tecflex for 100'?
Absolutely no reason you'd have a problem. But if you're making a 4-channel snake, this is a better solution:
https://www.redco.com/Redco-TGS-04.htmlFYI, it's the same stuff as the Mogami snake cable but with a different outer jacket that I prefer. Also cheaper!
2. Any reason to use fan outs rather than 4 xlrs on each end?
If you were using the Sommer Cicada, the conductors are only 26ga and even if you shrink each pair going to each XLR, it wouldn't be that durable. Famous like I did are the only way for this cable, IMO.
But like I said, use the Redco / Mogami snake cable for this instead of the Sommer cable. It will be simpler, cheaper, and more rugged.
3. My Weller station is failing, anyone have a soldering iron recc?
Pinecil all the way. It's a TS100 style, but with the better firmware already installed.
https://taperssection.com/index.php?topic=198135.msg23661694. Solder supply is 20-30 years old, any improvements since?
I haven't been soldering that long, but I always buy Kester.
5. Looking at the Switchcraft plastic stubbies for low weight, any good?
No, they are definitely lower quality as reported here and on JWSound.
You use stubbies for space and/or angle exit reasons. The weight difference is negligible. The plastic Neutrik chuck and boot assembly are very light.