Hi. I think if you want the dimensions for the PLM you can check the website
www.medalnet.net or
www.pourlemerite.org The first site is operated by Andreas Schulz-Ising. He is a very knowledgeable collector who can probably help you out. If not, Gretchen Winkler can probably help you on the second site. Her site is set up specifically to cover the PLM.
As for the pilot's badge, what kind are you looking to duplicate- Prussian, Bavarian, etc.? "Stogieman" on this forum can probably help you on that one. I am not sure who can help you on the Iron Cross but I am sure there is someone out there with the average dimensions. HF