I usually try to get 3 with gunnery because I don't take everyone into battle. I usually go in with the flagship and 3 or 4 other ships. Since the First Mate almost always has gunnery, I add Gus Johnson, George Eggel, and Cizzaro Fedeliti.
I stay away from a number of those that you list because their stats are terrible and/or their luck is atrocious. Characters with luck below 50 are: Manuel Melgoza, Louis Fareiro, Omar Kashani, Carmine Ragussa, Henry Mancine, Ivan Soledad, Fernan Pinto, Sabino Balboa, and Anthony Morgan. The last three are at least close to 50, so they are better than the others.
I try to make sure all my mates have above 70 in swordsmanship. That actually helps when firing cannons, just not near as much as the gunnery skill. At the same time someone with the gunnery skill and below 60 in swordsmanship is pretty useless for firing cannons (especially if their levels are already close to 20). Ok, that may be a bit overstated, but if their swordsmanship is low then the enemy can attack their ship and cut down on the damage anyway by wiping out your crew.
I've had 40 crew assigned to navigation (I wasn't planning on them fighting) that wiped out the crew of a Galleon.
Based on some tests run by someone else, courage didn't seem to affect damage caused by a crew firing cannons. Their test involved lowering courage by 20 points per test to see if the damage changed. That takes some set-up and I haven't had the patience to do that kind of test. 😀
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