Chuck has way more knowledge than I do, so I'll defer to him. But if those protrusions are the only issue, a Dremel would make short work of them. All of these are common as dirt, so I wouldn't feel guilty about modifying one to get your loco back on the rails.
Another thought: in 1948, Lionel transformed the 1666 into the early-style 2026. If you don't mind endowing your loco with that bulky radiator on the pilot deck, the front end parts for a 2026 might work. However, the pilot truck was shortened in the process. The revised geometry makes it a lot more prone to derailment. So the correct 1666 parts would be my first choice.