Hi Stewart,
I’m not building Mabel myself but have had a look at your build notes on the other forum and the problems you are having.
It looks to me as though the problem could well stem from incorrect valve timing i.e. the setting of the eccentrics. The valve dimensions given by LBSC are fine, indeed the port and valve dimensions are pretty standard for a 3½” loco. The face of the valve that moves over the port is 3/32″ wider than the port. This is the ‘lap’ of the valve and it’s this lap that allows the steam to be used expansively and hence economically. The total valve travel in full gear should be twice the lap plus twice the width of the port which gives 7/16″ (which I believe you have).
It sounds like the valve may be opening at the wrong point in the stroke due to incorrect setting of the eccentrics and you’ve corrected this by shortening the valve by a considerable amount in order to get it to run.
Setting the eccentrics on these types of valve gear (Allan, Stephenson, etc.) can be very confusing and frustrating until you have done a few! It’s very easy to get the forward and reverse eccentrics crossed over or the eccentrics leading the crank rather than following (or vice versa ! )
John