I wrote a long post this morning. When I thought I clicked submit post it vanished (sometimes I click post reply or something and I mess things up). I finally worked to posting something again.
Ted - Very well thought post and thanks for sharing your research.
I hope your suggestion that Lionel buyers care about Lionel on scale like equipment is wrong, but the truth is just supposed as opposed to known, perhaps Lionel could float an experiment on some Standard O cars without the "Blt by", either calling it a separate line of Standard O, or just put out some desirable Standard O cars and see if there are any complaints.
So briefly, although great advice for post 50's modelers, the patch suggestion doesn't work for me. From all the pictures I have looked at, Santa Fe attempted to keep its fleet reasonably clean and well painted. With exceptions like the war years, I think they were conscientious about their reefer fleet. Therefore I would doubt that a string of 8 or more reefers with patches wouldn't work that well. Like the Santa Fe, my reefer trains will probably be the most important freights.
I see some great weathering on this forum, SIRT comes to mind. For me, the problem is the pictures I see of 30's, 40's and 50's Santa Fe trains, and model railroads built by Santa Fe modelers (usually HO) at the top of their game, don't show models with a lot of rust and patching. That seems to start more in the 60's and later when maintaining looks became less important (like the picture you posted), than keeping maintenance costs down. Grime, dirt, and soot seem to predominate the earlier years, especially during WWII and a bit less so with the Korean War. I think the odds of seeing a string of 10 to 20 slogan SFRD reefers with patches in the same place would not work, at least for me.
Don't misunderstand my feelings about Lionel. I think they did a great job with their Standard O line. On Santa Fe equipment, I am surprised how exacting the research with regard to numbering and lettering has been. I could cite a number of examples how they have outdone the competition, but that's more for Santa Fe enthusiasts.
Please talk to them and if I go to York next month (I have the badges), I'll see if someone representing Lionel will pay any attention to me.
BTW it isn't only Lionel. When you ask what more could be done, in the past I have contacted MTH and explained how they could take their Santa Fe dies and produce more Classes of Santa Fe engines they haven't yet made. No more investment, just using different combos of tenders and engines and then numbering them properly. You would think that would get their attention, but they just keep producing the same engines with different numbers.