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I agree about the DE hulls being essentially the same. The 5" DEs were about 300' in length with the first of the DEs being about 20' shorter. The Buckelys had a plug inserted and I beleive the Butlers had another. I could forsee another 25' plug in the Butler hull being viable as long as the beam was modified as well to maintain the ratio.
The sequence (or, rather, partial sequence from later in the war) of actual DE classes, as you're probably already aware, was:
Buckley, 306ft x 36ft, 3" guns
Cannon, 306ft x 36ft, 3" guns
Edsall, 306ft x 36ft, 3" guns
Rudderow, 306ft x 36ft, 5" guns
Butler, 306ft x 36ft, 5" guns
Dealey, 314ft x 36ft, 3" guns
So, the hull was unchanged until the Dealey which, in real life, was the first post-war DE. Again, odd about the return to 3" guns.
I've gone about as far as I can in offering technical thoughts. You'll have to find someone who knows naval engineering, propulsion systems, and actual class performance to get much more info. Failing to find such a person, you're free to make your best guess.
That said, here's what I'd suggest...
1. Lengthen the hull by 25 ft but leave the beam as is. Adding a plug is easy from a construction viewpoint and has been done many times on many classes of ship. If you modify the beam, you've created a new hull and the Navy just wouldn't (and, in reality, didn't) do that. Again, depends on the degree of realism you want to adhere to. If you really want to increase the beam do it with an external hull blister rather than an actual widening of the hull. This has been done, in reality, on occasion.
2. Stick with 2 x 5" guns, main deck mounted, one forward and one aft.
3. Leave the propulsion system alone. I don't even know whether the Fletcher and DE's had the same system or not (presumably not). If they were different, it would probably be unrealistic to expect to be able to fit a DD system into a much smaller DE hull. Again, just speculation on my part. You decide. I know you're stuck on this point and you really want more speed but greater speed just doesn't seem that critical for a DE. You'll gain some speed by lengthening the hull (don't know how much) so maybe let it go at that.
4. Use the extra plug length to add your favorite combination of 40mm, 20mm, Hedgehog, torpedos. Maybe a midships Hedgehog and however many 40mm's will fit?
5. Keep the flush deck.
Good stuff!! Keep it coming.
Regards,
Bob