Funny that, Simon,
it turns out that I already have made a sailplan for the Hurley 22 - two sailplans, in fact.
The one with 70° yard is a smaller version of the one that my boat, Ingeborg carries. The one with 60° yard is a downscaled version of the same as Paul Schnabel’s Ylvi is using. Both these rigs have proven to work well.
If I were to choose, I guess I would pick the one with the Ylvi-style sail, to bring the mast a little further aft from the bow.
As for mast dimension, my guess is that anything between 130 and 150mm, with 5mm walls, should work fine.
Good luck!
Arne


(full size sailplans on Arne's sketches, section 8)