Here is my original post where I laid out my plans and asked for advice:
Thanks for everyone who contributed to the post above. The tournament went off without a hitch, I'll definitely be doing it again next year.

Here's the summary:


Particpants:
We had 40 players. Was hoping for more but based on the success of this year's tournament I'm think we'll be closer to 70. Of the 40 signups 37 showed up and 3 unexpected showed up so it was a wash. We discussed making players pre-pay (and possibly give a chip bonus for those who did so) but ultimately decided against it.
A couple lessons learned here.
1 - Start advertising very early, especially for a January tournament as Thanksgiving on is a blur for most people.
2 - Don't assume anything on Facebook actually gets read.
3 - Poker is not nearly as popular as I thought it was.
4 - Quite a few were inimidated about playing in a tournament after not playing poker for 10+ years. Will try to alleviate this next year by offering a intro lesson before the tournament starts.


Sponsorships:
I started a bit late on this but was able to get $500 ($50 per sponsor) to sponsor a table. Most of the sponsors will local to the small town. I was also able to get gift certificates from several restaurants that we gave out as raffle prize.
Lesson learned - Start getting sponsors super early. A lot of businesses have their chairty process automated now and in some cases need more than a 6 month notice to give anything away. Also this charity is a 501c which is a big advantage, some businesses won't even consider you if you don't have that designation.


Food (All Free):
8 large pizzas. All eaten
70 Fun Size bags of chips - about half were eaten
Popcorn - building had a popcorn machine, was popular enough
Mini chocolate bars - almost none eaten. Will be ditching this next year.
Trail Mix - about 75% eaten


Beverages:
Beer was $2, mixed drinks were $3. I think this price was optimal. Not nickel and diming people, also cheap alcohol helped with rebuys. Cans of pop and bottled water were free. Almost no pop was consumed, will just stick with the 2 liters for the mixed drinks next year.


Raffle:
Each entry got you one raffle ticket, additional tickets were $5. We did the raffle at the 2 hour mark. All the prizes were donated except the grand prize, a big screen TV that cost $300. From a pure P&L standpoint the raffle was in the red but we'll still do it next year.
It generates some buzz and rewards the players, focusing solely on profit isn't the way to go.


Help Provided:
3 girls acted as waitresses/bartender. Another guy in the back helped with this and making the popcorn. Another person helped man the desk for registration and misc. tasks until after the add-on period was over. I handled rebuys/add-ons, wasn't too hard. It did prevent me from keeping an accurate tally of how many people rebought/added on though. As people were eliminated many stuck around to deal cards at the table, etc.


Tournament:
10,000 starting chips. Rebuys for $20 gave you 10,000 chips (rebuy as much as you want the 1st 2 hours as long as your stack is <10,000. 1 optional add-on gave you 10,0000 chips.
Rebuys were a huge success. Add-ons were as well. Teh $20 amount was perfect, no need to make change and it was a more than reasonable price. We took cash/checks. I didn't get the Square reader out but will next year. We gave 50% of the buy-ins back (rebuys/add-ons went straight to charity) so $1000 in prizes.
We went 6/7 handed at the tables. Since people had to self-deal (which was abysmally slow to me but few of the players complained out lout at least) playing short handed seemed to work a bit better and also made the game more social.


Start Time:
After some miscommunciation we moved the start time from 10 AM to 12 PM, the pizza was served beforehand at 11:30. This actually worked out better so we'll be keeping it next year
1 - Gives people coming from out of town more time to arrive
2 - 12 PM seems like a more reasonable time to start drinking
3 - Playing 2 hours then taking a 1 hour lunch break would have taken out the momentum of the tournament. Surprisingly no one seems to get tired. We took a 15 minute break at the 2 hour mark and that was it.
4 - If you don't have a family, 10 AM Saturday is actually a bit early.


Duration:
Cards were in the air at roughly 12:15 PM. From 2:15-2:30ish we did a break and the raffle. Tournament was over at 6:15.
Other than that no breaks, people didn't seem to want them. Bathrooms and concessions were close enough that they could be attended to without missing a hand.


Other Prizes:
First person out prize went over well
High hand was hard to keep track of (Aces of 10s was hit in the first hour) and people kind of forgot about. Will drop next year.
Bounty - also went over well as the prize was a unique, custom deck of cards. Thanks for the idea of using a bounty chip. A few people got confused by the bounty chips. Will need to explain better next year that you only give your bounty chip to the person who knocks you out, the ones you've already earned by knocking players out are yours to keep.
First place also got a trophy and their picture (WSOP style) put in a frame hung in the local bar.


Tables:
We had 5 "real" tables and 1 circular. No one complained about the circular table.


Net Profit:
$2300 The rebuys/add-ons were the biggest driver here.

No poker is certainly NOT as popular as it once was, especially for these kind of events. But enough folks will usually still turn out for a well run event in numbers big enough to make it worthwhile. Especially if your "overhead" is kept as low as you can without loss of too much quality , you can keep it going. Good luck!

I'm glad that your event went well. I do have a few concerns.

By my calculations, you gave away about $1,000 of the $2,800 that you collected for the tourney (this may be incorrect). $2,300 less $500 from sponsors and assuming that the food/drinks were close to a wash.

In my experience, when the payback for a tourney is in that range (35%), you numbers will be down significantly for the next year. I'm not saying they will, but in my experience, I would probably adjust for a 25-30 turnout next year. You have to give away 50% if you are planning on yearly attendance. It is the most profitable for the charity long-term. Any charity tourney that I'm associated with that gives away 50%+ pulls in $3,000+ net on their tourney every year.

You absolutely have to do pre-sale. This will allow you to get a very good number and you may want to adjust your venue based on the turnout. A few years ago, we only had about 50 for a tourney and moved the venue to a friend's garage (or barn, whatever you want to call it). We had a slow-cooker brought in and catered the whole thing with a pig and fixins'. If this was for 100 people, that would have been impossible, but we were aware of numbers based on pre-sale. It ended up getting the most bang for the buck.

Good luck for next year!

I'm not great at math, but my estimate he made $2K and bout tree fiddy more...

If his net profit was $2,300 and he paid out $1,000 for tourney prize pool, then he brought in $3,300 total, assuming the food and drink was a wash. If he brought in $3,300 total and $500 was from sponsors, then he received $2,800 in buy-ins, rebuys, and add-ons. Therefore, he gave as prize $1,000 of the $2,800 he received from tournament players. I'm not sure where you are saying that my math is wrong.....

The point I'm trying to make is that, if you give out 35%, your profit next year is likely to be $1,000 and bout tree fiddy more.

There is only really two things you need to know about poker charity tournaments. One, if you are going to do them, then you need to find a way to make $3-4k consistently each year. Two, doing that consistently means that everyone that is volunteering for the cause will make minimum wage based on the amount of hours required. If your tourney is going to net $3k+, you are absolutely going to have 300 hours+ in it from all of the volunteers.