1) How much am I likely to be adjusting the lowers, 1" [25mm], 2" [50mm]? Looking at what I should make my block ratios to give me enough sensitivity/fine control.

2) What does the jib halyard/forestay tensioning wire look like fittings-wise? It looked as though people just use a large loop of the wire for the fitment to the s-hook of the tensioning system but not sure how to get the swage/nicro fitting to go through a reasonable slot in the mast without chewing the edges to pieces...

Thanks

John

PS things are advancing quickly and I hope to update my website real soon with progress pictures. 5 weeks to tentative launch date!

Lowers - 2" I reckon.  You only need about 1" adjustment but unless you have a bit more you will never have the adjustment in the right place & will run out on the purchase.  I've got the standard Jon Turner layout with a 3:1 on the side and 4:1 in between the 2 struts of the kingpost.  The jib halyard swage is small & the hole below the gooseneck is a hole not a slot on my mast - never had a problem.  Could you file down the swage?

With respect to the swage issue make the loop big enough that it never comes out of the mast.  To get it out you need to remove the sheave at the top.