I don't have internal routing and really don't want to drill my frame, so I wanted to see how others have routed/installed their external dropper posts.

Please feel free to share pics/tips of your setup.

I don't have a photo, but I installed mine with the wire and housing along the top tube; it's unobtrusive and works superbly.

I went under the bottom bracket and then back up, the idea being to maintain a gentle curve and to hide the cable a bit. I have PNW shock/dropper. It does both things surprisingly well.

Oh, pay for a decent lever.

I'm on my 3rd PNW style external post, tons of people make them and they all work the same way. They work great but are a huge PITA to rebuild when something goes wrong. They are basically the same post as their internal droppers but use a nylon string that runs from the bottom of the post that actuates the dropper up to the top where the cable attaches. The problem is the tolerances are so tight that dealing with the nylon cable when you have to rebuild the post is nearly impossible. I'm sure people can do it but that is why I'm on number 3. I try and try until I get pissed and go online and get lucky and see some site usually jenson dumping old stock for so cheap I just buy another one. When this one dies I'm drilling the frame. I never had an issue with my old KS eten external dropper but it is ugly compared to the PNW style.
Oh and my frame is setup for external droppers so it has the cable attachments for it but I'll just deal with zip ties when I drill the frame.

I’ve had 2 PNW Cascades (external routing) with no issues for a few years, but a buddy of mine ran into the same issue as you.

I don’t know if Gravity Dropper is still in business, but if so, their external Classic is really bombproof and easy to work on. Mine is 19 years old and still works great.

I don't really have a good pic of mine as I always take drive-side pics but here it is on my 2001 Stumpy. I have the cable running through some of the cable bosses on the tt.

zip ties, eh?