Question 1:
So what you are saying is, even though the cars are O or O-27 gauge and they should all be the same size for these gauges, the manufactures of the cars use
different methods to calculate the scale of the cars and also the time the cars where produced also is a factor on the size of the cars.
Am I at least in the same ballpark?
Just a point of clarification...people use the terms scale and gauge interchangeably. That is incorrect. Gauge is only the distance between the rails. Scale has to do with the proportion of the object to real life.
I'm certain this doesn't answer your question but please don't ask me why/how the various manufacturers decide to build something to what size they decide. I imagine a lot has to do with money.
There are no standards in O gauge. If enough of us would ever get together and pressure the manufacturers by not buying anything except whatever the agreed standard was that would work. It's also a pipe dream and incredible long shot.
Question 2: If you want to purchase a separate car for a certain train set like I did, what do you have to do to get the same size car to match the set cars?
Go to a local place and take one with you to match up or ask an on-line seller to give you the exact dimensions of the piece--many do.
Question 3:
Can anyone explain to me how you figure these scale ratios out?
The actual meaning of O scale is 1/48. It is also referred to as quarter inch scale mean one inch on the model is four feet in real life, i.e., a forty foot boxcar in real life is ten inches long in O scale.
I hope that helps.