The ideal shape for fire-bars in my opinion is wider at the top than the bottom, but not by much, i.e. enough to not allow any coals that do manage to fall through to stick part way. "T" shaped would also do. You could still utilise the notches, but build your grate in sections to mount in them. I f...
Undoubtedly there will be less heat below if there is no fire in the ashpan, the radient heat will to some extent be counteracted by the updraft into the fire-box not being pre-heated on it way past the ashpan.
Half a pound variation on a casting of that size and complexity, I would say is VERY close, and as it's not going to go to the moon, of no consequence at all.
Yeah, but that doesn't take into account inertia. The piston and piston rod has to stop and start twice each revolution, likewise a small proportion of the con-rod. That takes enegy too, so a lighter piston etc. will use less.