1) Using a scale ruler and photos, the rivet heads on the HL hoppers come out at 1.68 inches in diameter. Are they as large as 1-1/2 inches, or am I way off on my measurements?
Hmmm, hard to say without looking at the engineering drawings, but they're probably closer to 1 inch.
2) Z-bar channels on the car ends measures out to 6 inches wide overall, 3-1/4 inches width for the surface furthest from the car. Do these seem reasonable measurements?
The drawing in the CBC says they're 4-1/16" wide on the face and 3-1/8" tall.
3) Grab irons measure out to 3/4 inches wide. Too narrow?
4) The angle iron mounted at the cars' four corners, what thickness might these be? 1/4 inch? 3/8 inch?
You'd have to look at the engineering drawings for these, as the Cyclopedia drawings typically don't give those dimensions.