Excellent - I wanted to offer some encouragment, as I note replies to AoS posts can be a bit sparse...
I bought War by Sail after watching your run thorugh, I really like it's gunnery mechanics. It's gratifying to know someone else is following the same process of mixing features from various sources. I'm in the process of attempting to mash elements of KMH, War by Sail and Perfect Captian together, not sure it will ever be workable, but then that's half the fun isn't it?
Always interesting to see solo options, so the Gina Will's AI is on my list - thanks for the heads up as I would have missed that one.
I can't recommend JJ's blog highly enough - your Black Seas conversion ideas solved some serious head-scratching on my part and your finished ships are a pleasure to behold.