When riding the cross (the word "fighting" the cross is even more appropriate), the sub generates quite heavy forces.
Agreed - "fighting" is a word I'll be using more often than "dance" now...every movement is an attempt to escape the cross, and all efforts are futile.
An other idea from my brainstorming :
the interior side of the ropes (or even handcuff) could be bristling with metal studs. Specially designed to penetrate a little and tear off a few skin
No. This is far too dangerous with suspension. Stick to properly made ropes and cuffs, and make sure all your knots are well-practiced, and you have a plan to quickly end the scene if necessary. Prepare and plan for something safe, sane, and consensual.
As someone who wishes very much to experience crucifixion at least just once, but probably couldn't do it because of existing health issues, I would encourage you to take note: there is already a good deal of pain in the formation itself when done properly. The fact that the victim is always falling and can only dangle, straining every muscle to lift and breathe, makes it a full-body workout lifting their own weight, alternating between arms and legs.
You must be either very sadistic or you don't know the delicacy of torture: a little goes a long way.
Safer means of inflicting pain:
-nipple clamps (very painful and underrated around here - what better opportunity than when spread out helpless on a cross?)
-slaps all over body - especially the tender inside skin of joints - with the end of a crop
-a professional wand made for electro play (nothing homemade here - too dangerous!)
-a small vibrator that can move with the victim, like a Lovense toy (remote control power over intensity)
-an intense hitachi vibrator wand on the clit and nipples
-wax dripped from a candle
-clothespins along arms and legs
-(and for the bravest) a clothespin on the clit
The smallest movements can provide what you are looking for: extreme pain, screams, and tears without serious injury or damage. Start with your subject spread out and lying down, and practice small teasing movements to elicit and measure reactions. Pinching breasts with the right force is enough to lead to screaming. Work up to a kneeling position with arms down, then kneeling with arms spread out, then standing. Each of these positions are stressful when held for too long - a sadist might even train with a command to hold one's arms out in the crucifixion position, and force the victim to stand like that until they cannot hold their arms up. Time their endurance at this, and cut that time at least in half during the suspension because the bonds will add even more strain.
There is a clear divide between fantasy and reality on this site. As a sadist I once knew put it, "don't break your toys." Take good care of whoever trusts you with being tortured. Make sure consent is in writing and backup plans are established.
This stuff takes so much precision and care. Please be careful.