Just trying to decipher what wood the gunwales are was challenging as they don't look anything like ash to me. The yoke certainly looks like oak. But...the '94 Sunrunner were dark stained as standard prior to the finish coat of either Gunwale Guard or Watco exterior.
One possibility, the previous owner may have replaced the gunwales, seats, yoke and/or other brightwork. Although if they DIYed the replacement gunwales they did a superb job with the rabbet joint.
The deck plates do not look like stock MRC stuff, but I have never seen a Sunrunner in person. Actually everything looks so near pristine, including the SS screw heads, that I wonder if it was not rebuilt at some point.
More of the wood confusion comes when documents speak of "hardwood seat trusses" but then in the following sentence mention "standard ash-framed seats".
I think of seat trusses as arched one piece drops on each side of the seat. Those are sturdier than peg style drops. Like these
http://www.edscanoe.com/seathanger.html
I do not recall those peg style hangers in our 1990s Mad Rivers, but I always replaced that style seat drop with full truss drops and do not recall exactly what was there. Those look an awful lot like Old Town hangers/left over pieces of radius edge gunwale stock. The seat drop wood especially looks suspiciously different from the seat frame itself
Another document states that only the gunnels need to be oiled (as apposed to varnish) as they flex but further reading suggests Gunwale Guard be used on carry handles, decks, and seat spacers. So their thinking was the cary handles and seat spacers flex but the seat frames and yoke don't?
MRC wood gunwales were usually oiled. The seat frames, carry handles, yoke and etc were varnished. I would oil the gunwales and varnish (or spar urethane) the rest.
1) Anyone know where I could get the polypropylene, molded end caps, touch-up gellcoat, or even new-old-stock contoured seats??
I would not put molded (plastic) end caps on a wood gunwaled canoe, it just looks odd. The easiest way to make a new deck plate is to make it oversized and top mount it so the V shape is as wide as the outwales.
Eds canoe carries contour seats and Mad River replacement parts
http://www.edscanoe.com/32contourseat.html
http://www.edscanoe.com/madricarepa.html
2) Is there any potential problem with a very thin gap between the two-part gunwales on either side as resetting the screws does little to close the gap?
I would not mess with or worry about that little gap. The wales are rabbeted to cover the top edge of the hull material, which is a really nice touch.
3) Anyone have leads on one of these in the kevlar 55 lb or lightweight 44 lb version?
I would not do much to it except oil the gunwales and replace those peg style seat drops with truss drops. Make certain the end of the carry handles, thwarts and yoke are well sealed (multiple coats of varnish or urethane). Oil the cane on the seats.
I have seen a lot of canoes, and a lot of Mad Rivers. I have never seen a Sunrunner in person. I do not recall seeing another Sunrunner for sale.
In spec the Sunrunner at 12.5 inches seems shallow as a tandem tripping canoe, excepting a small, lightly loaded pair. Probably a fine day cruiser though.