I didn't know Canadian made Sea Hurricanes. I wonder if it was ever considered to fly them direct to the receiving carrier from the factory. Hurricanes could be flown nonstop to a CV in James Bay during ice free season, or with a single stop on the way to Halifax.
Or, send Hermes in 1940 from Singapore to Vancouver and load up the decks with crated Hurricanes for the RAF, plus Sea Hurricanes for Hermes.