Are you talking about the spring type choke that sits on the intake? It don't need a block-off plate. The spring sits in a recess but not through the surface. I may be wrong but a pic would help.
That don't look good. Sandbar is my thought also. A shop would cost more than you think. I'd wonder if there were hidden cracks in the glass under there from beaching it too much.
Heard about it a bit in ABYC class but haven't had a problem with it around here. Possibly when they first came out, they were not as good as they are now?
At this point it almost looks like it needs to be sandblasted or walnut shell blasted to see the extent of the damage. Patching just what you see now isn't the best route. Looks like someone coated it over before to get it looking better/stop leaking.
It might be just me, but Sierra cables have been an issue for me. Since I started using Quicksilver cables, they last longer. Sierra has improved most of their stuff over the years, but oem is for me.
Not sure if solar will keep up. I've seen a few at the marina, and if we have to move them sometimes the batts are low/dead. One has a wind charger propeller thing. It always is ok. Wind around here is fairly constant; cloud cover slows solar down a bit.
I currently am running three 1985-1985 3.0 MerCruiser's. Not the same as that motor but they are flawless. It's not the age, it's the maintenance. Keep in mind that I got these used, and don't know the history of them. If the op wants to fix up what he has he will have a good motor for his use.
You will be fine like that. I see shrink wrapped ones that use the arch for support of the shrinkwrap, with no support under the arch, just supports for the wrap on other places.
Most led's are 6-12 volt. Learned that a few years back, it gets cut down in the board itself. I've taked some apart and hooked them up directly to 12 volts and they work just fine, without the circuit board.
If the ducers are wired correctly and mounted far enough apart it should not make any difference. I'd put the map where it's easier to see, but fish are important to.