So most 'discrepancies' are mostly due to normal tube variation and biasing for current is the correct process.
What 'discrepancies'? There's no 'discrepancies'. We already went through this. The normal thing is to bias tubes up by current. Fender picked those #'s for the tubes they were buying. They checked enough of them and then probably gave them a little grace, lowered current draw.
I tend to forget they aren't perfect exemplars of the amp-maker's art. Just commercial products, made as cheaply as possible.
They were very good examples of tube amps. Very reliable, held up on the road, sounded great, looked good, easily serviceable.
They were not made as cheaply as possible, Leo could have made them cheaper, but then they wouldn't have held up on the road or even in town gigging. Think of Valco and others. He found a balance of making a good looking, good sounding amp that held up for the money. And the sales would seem to prove that.
Q: If an early tech had had no way to actively measure the bias current in a BF PR, wouldn't they have been fairly "safe" if they biased to reach -34V grid voltage?
Already been explained. If back then they got a hold of the same RCA tubes, then probably yes, but you
ALWAYS check bias when installing new power tubes,
ALWAYS.
Put in a new carburetor in a car, you set the corroborator for idol. Same thing.