Trying to disprove me - what were you thinking? :-)
Actually, congratulations on your well-reasoned article, much more exact than my off-the-cuff estimates of the percentages involved.
I don't have time right now to go into this more, so here are some suggestions:
1) Breaking strengths of 3HD and 6HD box can be narrowed down further by shortening the stick below the 2-bar at the top of the breaking column.
2) Relating cable weight to light steel weight and using short cable sections to refine things would be a bad idea because changing the connections on a structure has strange side effects. (witness replacing the 2 heavy steel sticks with light sticks and a heavy crossbeam, and both HD8 towers pop boxes)
3) Calculating Y for HD8 is erroneous because it's not the bar that breaks on this tower, it's the link box that pops. (Link boxes are still an open research question at this time.) Same goes for HD7.
I think pontifex would be more accessible (if not more fun) if the physics was more intuitive. A beginner will optimize his bridge by shortening bars to save weight (worked well in BB); pros will replace two long bars with one long bar and be more effective, but it's not easy to find that out.
If you think you'd get link boxes for free, that's not true because small bars are heavier per unit length - this is because of the proportionally longer diagonals and the absolute weight of the link boxes. Weight per unit 2HD=41, 4HD=26, 8HD=19 using VRBones's figures. Since a link box is stronger than a 2 HD bar, they're probably even heavier in proportion, making the penalty worse. And then there's the strength loss because of the diagonals' angle...