If a cylinder is rated for 2500 PSI, it will likely have no problem being bottomed out at either end of its stroke with moderate flow of under 10GPM at its full rated pressure for many thousands of cycles.
The relief valve should actuate fast enough to avoid too much of a pulse in the system. The rest of the system other than the cylinder is already taking this same pressure pulse when you hit the limit on the FEL, or any other hydraulic system connected to the same control valve.
You already have the right idea that whatever stops the motion has to be beefy enough to stand up to the force of the cylinder at full relief pressure. If your sheet-metal deflector was trying to stop the cylinder before it bottoms out, the deflector will bend before the pressure relief kicks in.
You can also get spacer ringsand/or adjustable threaded spacer rings to fit over the rod of the cylinder so that you can limit its stroke by bottoming out on the spacers instead of bending the deflector, but generally, the mechanism should be designed with the stroke and length of cylinder you plan to use in mind from the start.
The reason the hydraulic motor could not be connected to the FEL control is a mystery to me. The only thing I can think of is that maybe the FEL has too high of a relief setting?
Sometimes, you want a "motor" control valve to run a motor, but this is when you plan to leave the motor running for a while (like on a trencher, perhaps) and you want detents to hold it on for you. Also, for a high flow motor, the flow rate rating of a FEL control valve might not be high enough. Both of these are not issues in the case of using a small hydraulic motor to intermittently turn a chute.
In fact, I would think you would want the fine metering that is designed into a FEL joystick.
Also, having the rotation and elevation angles on the same joystick (connected in the right orientation and polarities) would make aiming the snow in the two directions a lot easier than having two different handles to mess with in perhaps awkward directions.
- Rick