Hi Ham385,
Making a Kibler kit would be the easiest way to go but you won't learn much about muzzleloading gunmaking. You will have an excellent example of a proper gun in front of you for reference when finished but you won't learn the skills to make that happen. Now don't get me wrong, that reference and resource is very valuable to someone wanting to learn the trade. However, it does not teach you how to make your hands do what your mind desires even when you have a Kibler model in front of you showing what a gun should look like. Moreover, it will be forever and always, a Kibler, and in most Kibler's posted on this site, there is little distinguishing them one from another. You are attempting a challenging project for a new maker. OK. Go for it but do your homework. There are many threads on this site describing inletting standing breeches and flat barrel keys. Use the search function at the top right corner of your screen. You have skills. Great! Learn the specifics related to muzzleloading guns like how to shape lock panels, how to model cheek pieces and forearms. etc. This site has a wealth of information about those topics. There is much information available on the internet but there is also a lot of junk. Most You Tube videos I've seen about muzzleloading gun building are pathetic and produced by people hyping wrong information and very mediocre skills. Let me repeat, address the challenge but do your homework.
dave
I appreciate your advice, and I appreciate you not trying to tell me to buy a kit.
This is a marathon for me, not a sprint. 100% I hear you. I get that some guys want the end result and paint by numbers is exactly the right amount of investment to have the satisfaction. I'm not that guy, for me it's about the journey, I'm willing to put in the time and the work.
I already have a flintlock, that I acquired last year and found to be in bad shape. I repaired the lock and tuned it when I ran into problems trying to hunt with it in the fall. All work I did myself. I replaced the worn out frizzen with a new one that required fitting. The frizzen screw was frozen and sheared off, so I drilled, tapped and replaced that too. I was having exploding flints because the angle of attack smashed the flints instead of scraping them. I replaced cock with a longer one but the hole for the tumbler pin was too large, so I had to pein it to shrink the metal, and file for a tight friction fit. After all that I stoned the sear to get good contact and a crisp break, and polished all of the mating surfaces. It throws great sparks now, I'm still on the same flint after several range trips, 2 hunting trips, and a ton of dry firing. I wish I had kept count on how many strikes, I've knapped twice so far.
I'm not saying all that to share how great I am, or a natural or whatever. It's the opposite, I didn't understand what was wrong and put in so many hours to learn about lock geometry. I could have just bought a L&R RPL lock and been done.
I'm just now embarking on the learning and information gathering. If you check back with me in 3 months, it will be likely I've nailed down the shape with notes and measurements and sketches, a parts list, probably a supplier(s), maybe even ordered the parts. A year from now I will probably have a complete rifle. Until I know what exactly I want, I don't intend to touch any wood. I have a LOT to learn.
In the meantime I have an acquaintance with a Peidersoli and a custom longrifle (I couldn't say who the maker is but he was quite proud to show me a few years ago) that I can reach out to and study the lines, shape, and positioning of the hardware, how the drop, the LOP, the cast fit me. I can ask around at my club, I'm sure there are a few Kiblers and maybe get lucky with some other custom rifles I can look at too.
I know, despite my best efforts, patience, and caution with every piece of material I remove, the first rifle is going to have something that's just not right, I'm ok with that, it's part of the journey. First time made a box the dovetails were bad, first time I made a handplane the mouth wound up much larger than I wanted, first time I made a table the stretcher shoulders were sloppy, first time I inlaid a medallion there were gaps, first time I made a bow the draw weight was 18 lbs. None of that meant the projects were ruined, just stepping stones that I was still proud of.