I found drastic differences between component libraries, and the “parts in my hand”. Some had larger leads then the outline specified, etc.
In making my own libraries, I used a plated threw-hole and increased it’s size (Drill size in Eagle) to about 0.125in for the BUF-634T. That size also seams to fit the LM78XX To220 things as well (with boards from BatchPCB).
When it comes to square leads, Never trust the PDF’s dimensions. Make a cheep measuring tape from the fab you intend to use (consisting of labeled plated threw-holes of increasing size, and measure the “parts in your hand”).