since I'm the reporter of this issue I weight in on this discussion in order to see if I can contribute in some way.
I think your proposed way is doable. A pity that it works only for a subclass of reinforcement forms ,but considering the fact that a more generic solution would be hard to find IMHO we can go this way for now and see if we can improve it further in the future.
In case of other rebars (i.e. rebar2) where this method isn't applicable we could fall back to the old/wrong way of doing things and write a corrisponding note to the rebar-shape-cut-list and reinforcement-bar-bending-schedule.
Concerning your calculations:
- cases 1 to 4: they should work fine (don't forget to take into account the stirrup hooks)
- case 5: I must confess that at first glance I do not understand your approach. Wouldn't changing the left/right cover result in an unintended change of the overall horizontal extent? Could you please explain it to me in more detail?
Cheers