A few answers
The picture is of prototype, version 4. I welded a tube for the cross bar with solid rods, so I could play around with different lengths. If the cross bar is too short, it can be hard to return from full deflection, as it is closer to overcentering. Too wide looks bad and is more apt to catch on things. Now that I'm comfortable with the lengths, it will be a solid 3/4" rod. I'm also toying around with an electric linear actuator for a future project. The rod has holes drilled in the end with the ends flaired, so as not to cut the line. The end of the sprit has 3 holes. One for the clevis for the turning block and the others for the adjustment lines which are secured with end knots.The block you see behind the light follows a turning block on the starboard back portion of the bow pulpit, so I could get all the control lines to the port side of the boat in a clean fashion. You can see pictures of the lines run through power cleats in the photo forum. This allows one person to easily adjust all the controls.My shop is set up for metal fabrication, including aluminum welding, so all the fabrication was done in my spare time.