One (AI) is the loneliest number...

After imagining all kinds of weird and wacky solutions, it turned out to be pretty easy to persuade the rear crossbar to behave. I just had to file one of the crossbar holes a bit, and I'm sure it wasn't so much as to create a weak point.

I still want to refinish the crossbars and akas, but have been too lazy to start on that. Once that's done, I'm just missing a mast, a couple of blocks, and some rope, and it'll be ready to sail...

that is what I was gonna suggest..... Maybe add a larger washer under the bolt head.  file . A little bit here, a little bit there and Bob's Your Uncle.

Bushy

Working on the old vs the new aka's, whats your opinion as to which is better?  Just curious...

That's a good question. I haven't tested out the old-style akas on the water yet, so I reserve the right to change my mind...

IMHO, the old style akas are better. There is a pin that holds them to the crossbar, and a simple bungee that ensures they'll never come apart. Although it's never happened to me, the snap-in (newer) system comes apart on occasion. There's plenty of discussion of this issue on the Hobie forum:

https://www.hobie.com/forums/viewtopic.php?f=71&t=57711

I suspect that Hobie moved to the newer system because it's cheaper to build and assemble, not because they thought it was better engineering. The older style required some precision tube bending and welding, whereas the newer style just has a bunch of plastic parts bolted onto (more-or-less) stock tubes.

Working on the old vs the new aka's, whats your opinion as to which is better?  Just curious...

That's a good question. I haven't tested out the old-style akas on the water yet, so I reserve the right to change my mind...

IMHO, the old style akas are better. There is a pin that holds them to the crossbar, and a simple bungee that ensures they'll never come apart. Although it's never happened to me, the snap-in (newer) system comes apart on occasion. There's plenty of discussion of this issue on the Hobie forum:

https://www.hobie.com/forums/viewtopic.php?f=71&t=57711

I suspect that Hobie moved to the newer system because it's cheaper to build and assemble, not because they thought it was better engineering. The older style required some precision tube bending and welding, whereas the newer style just has a bunch of plastic parts bolted onto (more-or-less) stock tubes.

I concur.  I like the first version better for its simplicity and reliability.  That being said, everything from 2011+ uses the newer style, so using the older stuff limits your options if/when something breaks.