This is a very non-trivial project you have taken on!
The 2001 National Jewish Population Survey estimated that there were about 529,000 Orthodox Jews in America: 324,000 adults and 205,000 children. The latter number matches almost exactly the count of children in day schools done by Dr. Marvin Schick a few years later for the Avi Chai foundation. A more recent survey shows some growth in day school enrollment.
http://www.jewishfederations.org/page.aspx?id=108513
http://www.avi-chai.org/knowledge-center/
There have been a lot of studies of local Jewish populations, most recently in New Haven CT. Here is a site with links:
http://www.jewishdatabank.org/community.asp
The Israel Central Bureau of Statistics publishes estimates of that country’s Jewish population:
http://www1.cbs.gov.il/reader/?MIval=cw_usr_view_Folder&ID=141
Their attitude is “a Jew is a Jew is a Jew” so they don’t break down the population by observance levels. A good estimate of the adult Charedi population might be obtained from the fraction of votes obtained by the Charedi political parties in elections; a good estimate of the population of frum kids might be found from school enrollments. Adult Religions Zionists are more difficult, though, as they vote for many different political parties.
Good luck!