I don't think you're over-obsessing. If I were making a drum for a percussion rifle, I'd make the thread journal 3/8" x 24, but the drum itself I'd turn to 1/2". That way, the drum bottoms against the side of the barrel flat TIGHTLY! This is important, as you don't want the drum to loosen and start to rotate. The obvious problem is safety, and the less obvious is the alignment of the hammer and the nipple. The 1/2" drum offers lots of material into which to drill and tap for the nipple seat too. The flash channel can easily be #10 drill. There are a few percussion locks that are cut for a drum, and I believe they are around 1/2" radius, but could be 7/16". It has been about 40 years since I last built a rifle with a percussion lock and drum and nipple, so my "memory is like a bunny's tail...short and fuzzy". Quote from my buddy Neil Hunter.
I'm in the process of acquiring a Bill Large barrel that I intend to build into a percussion Bedford Co. rifle, so these thoughts are also going through my melon too.