At the level of skill [fun-level] an inch of barrel is a no-mind, but IF you ever wish to compete at any level in the BP sport please be advised that target sights on revolvers are not permitted, else everybody would be shooting Ruger Old Armys and beating the heck out of the rest of the world who shoots 'as-issued' revolvers.

Making your own ball is covered in great detail in the book, BTW. I've also covered it on this site about a zillion times. Like anything involving molten metal, it requires care, concentration, ventialtion and protection. I see that you have expressed an interest in the larger calibre .44 Remington New Model Army. It's a good choice, as it has a one-piece ie. solidly rigid, frame, and is generally more accurate than any of the Colt repros with their two-piece frame and wedge system.

However, you'll get a LOT more shooting out of a pound of any kind of propellant with one of those sweet-shooting .36cal. Say 25gr for the .44 versus 15gr for the .36...your choice [280 shots versus 466 shots].

More ball to the pound as well - a .44 weighs around 126gr [48 to the pound] and a .36 weighs about 80gr ]87 to the pound].

tac

PS - my name is not Frank