The info I have:
standard displacement increased to from 22,000 tons to 23,000 tons (you can do a lot with 1,000 tons)
different elevator arrangements - still the same basic size elevators but having one platform that serves both hangars
improved machinery, more efficient (basically similar to the Illustrious class) including improved rudder arrangements
improved internal arrangements and compartmentalization
improved/increased emergency services
heavier catapults (accelerators)
crash barriers
primary AA moved to the gallery deck (for better coverage of airspace)
some rearrangement of armour
still 64x large or 72x medium size folding wing aircraft
Plus by the early-war you would have had:
various radars including air search and AA FC
fighter control center, similar to those onboard the Illustrious class in the MTO
outriggers for additional aircraft (probably 5x) as in Illustrious class
increased light and/or medium AA
Ark Royal came out heavy, despite a lot of welding being used in her construction. Designed for 22,000 tons standard displacement on completion she was 22,585 tons (declared under WNT rules at 22,500 tons). But there were discrepancies between the calculated weights (as noted above) and those revealed by actual inclining experiments. The latter brought her out at 22,870 tons with full ammunition load. Some of the early 1934 figures showing her at 22,000 tons included only 75% of both ship and aircraft munitions (but space was provided for the full load). That was coupled with a hope that weight could be saved during construction. This was done for a number of British ship designs of the period. So there is less margin to play with than might be assumed (data from Friedman "British Carrier Aviation").
As for aircraft numbers, and remembering that was driven by hangar capacity, the final design dated 3 May 1934 was given as 48 torpedo bombers and 24 fighter/recce aircraft for a total of 72. The latter were to be the Hawker Osprey. But by 1938 it had already become apparent that due to increasing aircraft size she could not accommodate those numbers. Friedman quotes estimates of 40-44 Albacores and 12-22 Skuas (52-66 total) but some of the larger combinations meant permanent stowage on the lower lift platform. 60 was considered the max for sustained operations and maintenance and the hangar fire curtains were arranged accordingly. On the outbreak of war she carried 42 Swordfish (4 squadrons) and 18 Skuas (2 squadrons) for a total of 60.
Quite what her capacity would have been with an Albacore/Fulmar Air Group is open to question as these were 3-4 ft longer than their predecessors. Her air group seems to have dropped to about 54 when she replaced the Skuas with Fulmars, but it is not clear if that maxed her hangars out. One problem in assessing her capacity is that, unlike the Illustrious/Implacable classes, the lifts occupied floor space within the hangar, so how longer aircraft might have fitted in/around those I've never managed to work out.
Increasing the hangar width from 60ft to 62ft would have helped come 1940 in view of the decision that the folded width of fighters should be 13ft 6in (Firefly, Firebrand F.I and Seafire III/XV/XVII all met that requirement) which allowed 4 abreast stowage in the hangar with adequate working room.
No change to the power of the machinery was necessary. Designed for 102,000shp and 30 knots but on trials at deep load she made 103,000shp and 31.2 knots. Illustrious was designed at 111,000shp for 30 knots. Only with the demand for more speed from the Implacable in 1938 to 32knots, (which has never been fully explained) did a new 4 shaft machinery layout have to be used to produce 148,000shp. Increasing speed by a few knots around that speed point comes with a significant cost.
Accelerator/catapult power was not so important in an era when free take offs were the norm. But in 1938 the BH.I as upgraded was capable of launching 12,000lb at 56 knots in zero wind (having started at 8,000lb in 1935). The prototype BH.III of 1940 (as fitted to Illustrious in 1940) was capable of launching 11,000lb at 66 knots in zero wind. The BH.III was then upgraded as WW2 went on. These figures were comparable with USN catapults of the same period.
Ark Royal was the first RN Carrier to be fitted with a crash barrier (sources differ as to whether this was fitted on completion or during 1939).
Increased compartmentalisation comes at a cost in space and weight terms. It can lead to inefficiencies in actually operating the ship as was found in the Midways. Ark's biggest weakness was the routing of the boiler uptakes across the ship so close to the waterline. That was something that was not realised until she was lost but then quickly acted on in terms of modifications to carriers built or building and to the design of the Audacious class.
I don't follow your armament comment. An early design for Ark had 16 single 4.7" AA at lower hangar deck level. It was March 1935 before the twin 4.5" was adopted with the 8 mounts being placed on the upper gallery deck at a cost of 150 tons. The spacing was to reduce blast interference between mounts. Friedman notes "Presumably it was impossible to place twin mounts on the lower hangar deck." Sponsons for them would have then had to be larger and more liable to damage in heavy seas.