These are for the Fetters, or early, Challenger:
Smokebox - 2 7/8" long by 2.089" dia.
barrel - 1 7/8" long by 2.145 at smokebox; 2.170 at throat sheet (front of firebox)
Firebox - throat to cab front - 4 1/8", mud ring is 5" long.
Shape of firebox is hard to describe - mud rings are parallel, but the top tapers down and slightly in as you move aft.
Plan 117 in the MMR Cyclopedia will help. Dimensions above are from a prewar Lobaugh boiler. I think the whole thing can be done with 2" dia bar rail and .020 sheet.