HI Bob,
I know what you mean about the drawings, there are a few things I noticed myself, especially in the boiler drawings, The firetube positions are not dimensioned, and there is no view of the smokebox tubeplate, for starters. I also noticed that my drawings are printed slightly larger than full size, so can't easily measure off the drawing for missing dimensions
I see what you mean about the contradictory measurements of the fromt of the pilot beam too, the side view of the main frame and pilot beam gives the pilot beam as 3/4" tall, but the measurements on the front view of the piolot beam are 9/16" + 1/8", making 11/16" height in total, 1/16" less (see, I CAN work in Imperial, lol). Your idea of making a 3D CAD model is a good idea, may help to sort out discrepancies before you "cut metal". In this instance, I would say, try to change the 1/8" for the top section of the pilot beam to 3/16" and see how it looks.
I can't figure out what those slots in the pilot beam front actually do, or are they just copying the shape of the full size original?
GLR still seem to be alive – now trading as GLR Kennions Ltd, – and they have several Josie castings advertised on their website, as well as some suitable wheels. I have them bookmarked for when I start my Josie 
John, really like the pic of the 2-1/2" Josie.
Ricky