Since your using SW 2016 look into the "mate controller" they added this year. I have been able to make some nice videos very fast with it. I am not sure how it interacts with configurations, but you can likely copy the numbers from your configurations into the mates and do it quickly.
If this is a single replacement part, and the function is not obvious I would wager with byrdj on evolution.
The inner screw was most likely the original design and when it didn't hold well enough they added the external clamp.
I have done some work with hopper feeding pre-cut and straight steel wires. Our hoppers use a roller at the choke point, where your sheet metal is bent. These rollers actuate (45-90deg.) each time we feed a part, we actually tie the air cylinder to the escapement. The gap is still there but...
Everyone has interpreted the tolerance correctly here, and hopefully one of them makes sense to you.
The way I see it, different tolerances have their place to show design intent. +x/+y, +0/-x, +x/-0 and +x/-x all tell you very different things about design intent of that part or fit.
That being...
This may be a bit out there, but if you have a rig like that you should already have a winch up front. If it has a remote control maybe you could find a way to use it. I'm seeing a few pulleys connected to a hoist mounted to your B-pillar that would get you up where you need. Just get a...
I have had a similar problem on aligning drawing views. I found that the order you select things to align makes a difference. Mostly that I have had to select one drawing, select the align option, and then select the second drawing to align it to. It may be similar for your problem.
If you have higher torque loads and lower speeds you might look into agricultural CV joints instead of the automotive ones. See Weasler or walterscheid.
If you are talking about the spline that transmits torque to the CV then, more surface area means more strength, but it is harder to slide.
Ralph,
Try playing around with the "design study" tool. It's similar to a "goal seek" in excel. Start a design study, choose your variables (length and thickness), add constraints, if needed and define your goals (weight/mass)
I haven't included center of mass in anything I've done but you might...