Shelby, measurements are "as is" with felts.
My analysis identifies Kd=76.5% and Pd=58.6% as ideal diameters for the king and pawns (IMHO). Following these ratios not only sizes the king and pawns to the appropriate chessboard, but it also ensures that the king and pawns are properly scaled to each other.
The following is a simplified formula that ties it all together, where S equals the square size.
S * .765 = Kd * .765 = Pd
For example, for a standard 2.25" chessboard:
2.25 * .765 = 1.72" * .765 = 1.32"
(Kd = 1.72", Pd = 1.32")
The following tables provide dimensions for the most common size chessboards. The first table shows the exact results of the calculations. The second "working" table adjusts the dimensions to their nearest fractional equivalent since it's easier to measure to the eighth-inch than it is to the hundredths of an inch!
Shelby,
With all the minor changes along the way, what are the final dimensions of the plastic and wooden sets? Are they similar to the dimensions of the Ultimate Butterball set below?