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Yes, the fillet is a common thread relief and for strength as a square corner would fracture. However, I'm beginning to believe that it has nothing to do with the question at hand.

With the threads at 7/8" (actually slightly less than .875") and the bottom of the fillet being about .81, that's a considerable difference over which to press a hard washer.

Putting the drum back on, I realized that the washer's tang is external and that the depth between the face of the drum and the end of the taper is almost 1/8" so the washers must be about 1/8" thick and I would bet that the inside diameter is 7/8". Any settling into the groove is likely from wear.

These dimensions, of course, would apply only to Henney Packards.

Here are some photos of a new axle seal. The material appears to be leather with one side smooth and the other side rough. Thickness is 5/32'

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Thank you, that is very helpful! How far does the tang protrude? Of course with Henney, everything was on a much more grand a scale so much larger but should be the same idea.

The tang length is about 3/16" and the width is about 11/32"
The seal in the photos is from a rear axle seal kit for 2213 and 2313 commercial chassis

The 2213 and 2313 coaches show a different part number as they do for most parts. Do they have 7/8" threads on the axle?

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Yes, they do

Thank you again. The key on my axles is 5/16 and I got all the pertinent measurements yesterday that seem to match yours but I also put out a call (email, actually) to see if the original blueprint is available. If it is, it will certainly take out the guesswork, especially in regards to the material specification!

From the original blueprint I was able to source material and have several of the axle seals made. They are called Rear Axle Shaft Nut Oil Seal and are part number 426961 but it's still not clear what their purpose is! No matter, if it's supposed to have them, then it will have them. I also bought a differential carrier gasket to help amortize the shipping even though I do not have plans to disassemble it. I guess whether I do or not will depend on finding any major leaks but I don't expect any.

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Don,
Are these all junior cars?
facebook.com/commerce/listing/941457443258243/?media_id=0&ref=share_attachment

What about this one?
ocala.craigslist.org/pts/d/bushnell-pack ... arts-and-parts-cars/7270384543.html

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The one in the photo is a senior and so is the one on Craig’s List. The Facebook link took me to an Imperial photo so no answer there.