I’d not worry too much about the safety-valves either though I think I’d want a lock-nut on the stem.
It’s hard to tell the exact shape of the lever, but in that form its contacts with the valve heads ought be semi-circular.
.
I take you point about the problem with establishing the structure of the welds, if this boiler is of steel. I am not though really convinced that mild-steel is somehow any different for having certificates of conformity – they supposedly say only that the metal consistently meets an industrial standard, not whether it is suitable for a given application. It still goes rusty! Far more important is the structure and weld quality, and no, those will be very hard to assess.
Do we really know what this boiler is made from, though?
I don’t have the original drawings for my loco but do know it was built more or less just by copying the LBSC ones by time-two on the dimensions – but copying fairly liberally. Its original boiler, back in the early-1980s, doubtless used whatever off-cuts of standard pipe and hot-rolled steel plate happened to be available, though it was welded properly.
I’ve just tried to obtain the basic sizes of its replacement boiler, of copper. It had to fit the same space including smokebox diameter (also apparently made from ordinary steel pipe) and slightly <6″ width between the frames, so its shell is of 6″ internal diameter, roughly 17″ long between tube-plates. Whatever LBSC had specified.
As far as I can measure it by tape-measure, the grate is only about 7″ long by 3.5 – 4″ wide. (The grate and ashpan do not fall clear of the locomotive; the grate swings down to drop the fire. So not easy to measure.) 9 half-inch tubes, 3 superheater flues.
So not very dissimilar to this traction-engine, at least in overall size.