Best Of
Re: Pump Size
draw up a quick sketch of what you are thinking. Generally I would puut the pump pumping towards the source of pressure drop, in this case on the return pumping into the heater.
Re: Sq ft of steam:sq ft of EDR
Personally, I look at the gross output spec and do my own math.
For most who are confused by this stuff, I'd say go by the steam EDR spec of the boiler and don't add anything to your number and try to get the boiler number as close to the radiation as possible. Preferably being slightly under on the boiler side. If the boiler says it can do 325sqft and you've got 300-350 I'd call that good. If the boiler says it'll do 325 and you've got 250, even 280 I'd say no dice, go down a size.

Re: Please comment on a boiler re-install
piping it primary secondary is the proper way to isolate the circulators. 3/4" copper is only good to move around 50,000 btu/hr so the piping for all of it is too small. 3/4" pex is even smaller than copper.

Re: Steam Trap
It's an O-E return elbow, as illustrated in the upper left of the "Vapor Devices" scan. Also appears in chapter 15 of @DanHolohan's "The Lost Art of Steam Heating". And yes, it should be vertical.
Re: Sq ft of steam:sq ft of EDR
Your statement makes no sense. The boiler rating in sq ft accounts for the pickup factor. So adding in:
"Steam ratings are based on the connected radiator EDR and does not account for any pickup factor." would be a factually incorrect statement.
Re: Sq ft of steam:sq ft of EDR
So, is the 996 sq ft rating on the 64-08 actually 749 sq ft when you take out the pickup factor?
My EDR is 332 sq ft, but a radiator was removed at some point by a previous owner that I would like to reinstall. This will likely take the system to 360 sq ft. Would the Peerless 63-04L rated at 383 sq ft be ok? My current boiler is rated at 479 sq ft.
Paul posted an excellent chart for the Peerless 64 above.
Take a look at "gross output" for the 64-08. You will see 318 for steam. This is the output after the combustion efficiency is included in the data. You lose 81 KBTU out the chimney.
Now look at the "net ratings" for steam. You will see 239. The manufacturer assumes that you will need 33% additional capacity so they rate the boiler at only 239 KBTU despite the fact that its output is actually 318. The 33% reduction has been a bone of contention around here for years.
If it were me, I'd use the 63-03. 98 KBTU yields 408 sq ft. You'd have a pickup factor of 48 sq.ft (360 EDR)…………..12%. Plenty if you insulate the piping and install it per the manual. It will never cycle on pressure.

Re: Severely corroded steam boiler
I am happy to stick my neck out here. Based on what's pictured I'm going to say, not only is it oversized, it's comically oversized. I'd Bet money there is no more than 350 sq ft of radiation in that house. If that's the case they should have installed the GSA-125, the GSA-150 at the absolute maximum.
Do you have pictures of the installation of the new boiler? I ask only to see if they installed it correctly. The sizing is super easy, so if they can't get that part correct, I have doubts about getting the installation correct.
Agree with above, there is plenty of talent listed on this site for NY, some of the best in the business in fact.
Re: Gas Boiler Question
I might compose a letter if I were you, that indicates that the contractor did not install the boiler according to the manufacturer's instructions. Then report this poorly installed job to the state licensing folks. When a contractor gets a letter from the State licensing people, the contractor listens.
You can do this yourself at very little cost to yourself.