Tim,
I don't know how experienced as a builder you are, but here's some more info.
1. If you use Rod England's parts, you must use them all and they are expensive. That means you must use his barrel as well, and it only comes in .45 caliber. There are no other barrels currently being produced that will work. I looked for years to find an alternative after Badger quit producing that profile for Don Brown. Seems like overkill to build an expensive match rifle to hunt deer with.
2. With Pecatonica's components, you can use any one inch, octagon barrel in whatever caliber and twist you desire. Smaller calibers result in less recoil. A .45 cal shooting a 530 gr. bullet kicks as hard as a 45-90. Pecatonica's stock profile is in the pistol grip style. If you want a straight grip, go with Track's sporting rifle components (if they have them in stock).
3. With a 1" barrel, you must use L&R's bar lock and drip bar. The Davis Alex Henry lock is designed for barrels larger than 1". Their drip bar won't fit and the lock is taller than the L&R in profile. While this doesn't seem like a problem, the reveal around the lock panel after the lock is installed is determined by a break point located on the standing breech. The gun will look funky with the Davis lock.
4. Whichever system you choose, There are two precise holes that must be drilled. One goes thru the forward part of the trigger plate and into the center of the standing breech. The other goes thru the tang and must hit the center of the 5/16ths post at the top of the trigger plate. No room for error. It isn't a job for a hand-held drill. Also, with Rod England's components, you will need a set of 60 degree countersinks to fit all the screws.
4. You will have to have a special mold cut for your bullets and probably a sizing die as well. There are no commercial molds being made for muzzleloading bullets. The bullets are generally .001 less than bore size to give a slip fit requiring the weight of the ramrod only to seat it. Any smaller and the bullet can move forward while you are carrying it in the woods resulting in a dangerous condition. Even then, you must remain aware. Match rifles aren't carried around the woods, so this is less of a problem with them.
I have a fast twist, .40 caliber, one inch barrel available. It's 35" long. If you are interested in it, we can talk about it more after I return from Friendship.
