... I looked at separate adjustable cathode bias but I think the wattage that is needed for the pots I am finding hard to find. ...
2w pots, RV4 style (the ones I have gotten are generally PEC RV4 pots). They're kinda expensive, but it's not like you need 5-10w pots, because there are a couple in the circuit and the other resistors also dissipate some of the power.
... you never know if new tubes are matched unless you check ...
RDH4 says power tubes should be matched by testing
power output of each tube in a power circuit (similar to the intended application). Show me a tube vendor that does that... Idle current is probably also a useful test, as well as Gm at several plate voltages, etc.
Why should we listen to RDH4? The guy who edited it worked for AWA, which was an Australian tube company who eventually became RCA's manufacturer for that part of the world. Aside from getting double-checking by other folks in the industry, he knew the stuff directly from the tube designers and manufacturers.
... Maybe today we focus too much on idle bias, but at what point does a mismatch cause problems? ...
An interesting section in RDH4 is Chapter 13.5 v,
Matching and the effects of mismatching, pp 580-582.
My Hickok tube tester has a Good-Bad "English" scale, where the bottom edge of the Good range is equal to 60% of the Gm for a bogey tube of the type being tested.
Anyway, RDH4 has an example of the effects of mismatching wherein they pair a 2 different output tubes (a 2A3 and a type 45) in a push-pull stage to see what will happen. Amplification factor for these output triodes is 12% apart, but there is a more than 50% difference in Gm and plate resistance. By the standard of the Hickok tester, 50% low Gm would be the same as a "Bad tube".
The end result was 5% 2nd harmonic distortion (2nd normally cancels in matched push-pull stages), and a shift in tube bias due to rectification. All-in-all, you call it "less clean output power".
What other effects might happen in radically mismatched tubes?
Hugely mismatch idle current may cause hum in the output stage (which would normally cancel in the OT), but you'd almost need fault current conditions for it to happen (part of the reason I think you hear hum in the speaker when plate current skyrockets in an amp). Huge imbalance, especially under driven conditions, might cause early saturation of the OT core (which is intentionally small in a push-pull OT) meaning less power at as-low a frequency.
So if you need maximum clean power & maximum bass authority, then well-matched output tubes is a good thing. But for most practical purposes, in a guitar amp (where we intentionally have ENORMOUS distortion by hi-fi standards) it just doesn't seem to matter much.