Hi Brando753, the actual holes diameter is 6.4mm, between-centers distance is 14mm. But I'd strongly recommend to wait for the station to arrive and measure factual dimensions. It would be frustrating to get PCB manufactured and then find that AiXun have made minor adjustments to the back panel and called it version xx.yy+1 ...
I don't recall what the wire gauge was - I used the original wiring, just re-soldered connections on the back edge of PSU board (they were subpar), and snipped off one of the ring terminals as one wire was to be soldered into the new PCB after my modification. For the one additional wire - its gauge is not critical, it only carries current for the LED in the optocoupler (~2 mA) and both ends are soldered, no crimping on that one either.
As for putting the TVS inside of the connector - I assume you are thinking about putting a TVS into the handle's connector... If so - then the answer is no, it will not be a proper ESD protection. The problem is: if your handle, while disconnected from the base, have gained significant ESD potential - the TVS in the handle will not be effective, as it is not having a path to ground for ESD potential to be discharged to. Until the handle is connected to the base, of course... but when you connect the handle there is no guarantee that the ground pin will make contact first... so, your ESD-charged wires leading to MCU inputs may make contact first and the ESD event will happily occur, frying your MCU input(s) before the ground pin have made its contact thus "enabling" TVS protection... A kludgy attempt to mitigate that would be to have a longer pin for ground in the connector (similar to how USB-A male power pins are longer than the data pins), but that is both unrealistic with the GX connector and simply not an elegant engineering solution. Hence - either open up the front panel and modify the MCU PCB, or go the route I went for. Good luck and have fun doing whatever you will choose to do!