Thanks for the suggestion , any particular reason for the choises other than the cost ?
There isn't any real advantage to one solution over the other, though be aware that there are two basic families of Mesa cards, the DB25 ones and the HD50 ones.
The HD50 cards have been around longer, and are possibly a little more general-purpose in their focus. I get the impression that the DB25 cards are maybe more hobby-CNC biased.
If you want to use resolvers then you need to use the HD50 cards as the 7i49 is HD50 only. The 5i24 is probably the best bang-for-the-buck as far as pin count goes, if you are building a PCI based system,
Both families of cards support the smart-serial interface cards so there is no reason to prefer one over the other there. You can run more RS422 devices from a 7i44 than from a 7i74, but that's unlikely to affect many users. (both support 8 x smart serial cards)