The OP said "never see it again". That implies no access... I suppose it is tough to imagine zero access for a modern borescope.
In sailplanes, the operator still has a functional check, and a way to inspect and repair as needed. That is different from "bury it and never look at it again", which is where my alarm bell went off.
I do suppose we do "cut and repair" to refuel submarines and fix failed human parts. We would still need to know it is a rare event rather than a regular thing...
The fact that linear bearings are pretty much trouble free is an important point for design of the OP's system IFF he is doing the whole thing as in a sailplane. Deviate anywhere, and the assumptions on reliability are lost, you start over, and regular inspection really ought to be provided for until reliability is demonstrated. I have this vision of an 0.035 wall tube being worn away. Without a visual check once in a while to catch a worn tube, it could locally buckle and lock the ailerons... that high value failure mode should justify some fuss.
When the linear bearings common in sailplanes do have issues, what are the failure modes, and how is it detected prior to major control issues? Yeah, lots of FMEA in my history...
A regular borescope inspection could stand in for a normal port and cover until a repair is indicated. The builder could even build the skin with port prepared but not cut similar to what is done with fabric, then the port is cut only when and where needed.
Billski
