Keith:
You don't want to copy my POS trailer (a $140 harbor freight steel trailer). You already have one of the best trailers out there (Trailex) (yes I'm really jealous).
But perhaps temporarily until Hobie gets their cradle act together you can throw a PVC bunk on there. I would hate to see you cut up a perfectly good set of Hobie cradles just to make it work, especially since you now have both the old and new versions of the AI (the PVC bunks will work on either, without needing to change anything)
Here is a pic from the back of my POS trailer, you can see I have already started replacing rusted out steel with aluminum as it dwindles away (lol). Ignore the big brown thing on the back, that my foamcore planing hull mod to convert the hull from a displacement hull type to a planing hull, it weighs 6 or 7 lbs and adds about 80 lbs of additional floatation to the boat, the extra floation in not really needed to counteract the 55 lbs of motors (27 lbs ea), but as you know I regularly overload my TI (always way too many passengers and gear it seems), and it helps a little, plus the hull mod allows me to get up to 12 mph cruise (vs the previous 8 mph from the old displacement hull) ( I'm describing the thing here in more detail referencing your post on the WT forum, just FYI). I only need all that extra junk because I'm mostly offshore in open water (the Keys are really really big, and really dangerous lol)).
Here is a close up of the super simple roller I made from a paint roller, some PVC tubing, and some angle iron (it took 30 minutes to make with a drill and hack saw, and cost maybe $4 bucks)
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Hey it ain't pretty but it really makes loading the boat easier especially on steep boat ramps.
On the main bunks I used 1" pvc tubing, to make it a little stronger I jammed in wood broom handles into the PVC (wood is lightweight and amazingly strong, and completely protected inside the PVC). Many others are using 1 1/4 or 1 1/2 PVC which is stronger and probably works equally well (probably don't need the wood with bigger PVC) everything is mounted on around 11 inch centers. On mine I just placed the boat on the PVC pipes, letting them find center themselves, then just marked the spot and screwed the pipes down in a couple points (don't need much).
There are many threads of other guys doing the same thing. Not pretty but hey it works...
Hope this helps
Bob