I think your recollection of Queen in eighties is driven by very optimistic documentaries. Nobody outside of UK was taking Queen seriously until Live Aid. They were considered to be a bit of a joke - rock cabaret, riding bicycles, looking for fat bottomed ladies while doing fandangos. "The Works" was doing terribly in US. It didn't even make it into top 20 after release. "Radio Ga Ga" reached number 16 for one week. "I want to break free" didn't even break free to number 45. US leg of "The Works" tour never materialised, they went to promote the album end of August/beginning of September 84, they were back home mid October. They went to play Rock In Rio and on the first night people boo'd and thrown stuff at them on the stage. On day two Freddie reinvented the schtick, stopped wearing fake boobs and leotards and they pretty much did rehersal to what you saw at Live Aid.
My recollection is from personal experience, I was a Queen maniac (still am to some extent). The works tour played to crowds of 300k in Rio (as part of the Rock in Rio). Not being as successful in the US doesn't mean they were not successful globally overall. Besides The Works album went 'Gold' in the US On April 24 1984, and was one of their more successful studio albums in the US, obviously some time before Live Aid. Live Aid didn't really help their popularity in the US which didn't really recover until Freddie died in 1991. His death (ironically) revitalised his career in the US, not Live Aid.
The Tour went from August 1984 to May 1985. In October 84 they were playing a lengthly set of dates in Sun City South Africa, which would be difficult had they been back at home in October as you said. There was never a US leg planned, some speculate due to Mercury's voice not being able to withstand a full on US Tour, but no one really knows why and it's been speculated about ever since.
Equally you are right that some fans (allegedly iron maiden ones, but in reality it was a reaction to his being dressed as a woman and he removed the clothing and continued which calmed it all down, the 1980s not exactly being the most enlightened of decades after all. ) booed and threw stuff at Mercury when he came on dressed in the "I wanna Break Free" drag act, which was not repeated, but again if you watch 'uncut in Rio' it's hardly how you describe and is, as mentioned and it wasn't the first time fans threw stuff at Mercury when he dressed up or changed his appearance. In the main, the crowd are pretty much as they are in most Queen concerts.
I must admit, at the time I didn't like the video and by association the song, mainly due to ingrained common prejudices of the time...men, especially rock gods just didn't dress as women and that is more about common prejudices of the time rather than the popularity of Queen as a whole.
Also again, you are right that I wanna break free and by association The Works were not as successful in the US as in Europe, but given the MTV and Radio Station ban on that particular track and it's obvious effect on sales and exposure in the US that's hardly surprising. It's also not out of step with Queens popularity in the US overall, The Works charted very well for Queen in the US...higher than the album A Kind of Magic which came after Live Aid.
Ironically your recollections seem entirely based on the press reports rather than watching the footage or considering the circumstances at the time.
Check it, see how many dates they played on that tour, where they played and when the album became successful outside of UK.
I think you need to, your tour dates specifically.