Hi Kris,
I just measure the outside diameter of the standard (unaltered) plastic bobbins I have and they are 0.800 inches.
I also measured the inside diameter of a new Coghlins plastic matchsafe and it is 0.810 inches. The bobbin is a near friction fit; the problem is that the match safe does taper slightly downward so the bobbins in the bottom of the matchsafe will have to be reduced slightly in diameter.
Looks like you have a good idea here, it just needs some tweaking. Thanks for filling us in.
Concerning your wife and mystery packages (mine are from MEC), I have them delivered to my office and bring them home gradually. Once the new item is absorbed into my pile of old equipment then "I have had that thing for years"!
Mike