Lots of great information. I don't know much about military guns, so this has been really helpful.
I would think our kit selling price for a Bess would be around $1450 - $1500. This is based on what we need to get for our fowler, plus some of the added complexity. It would be, however very complete and easy to assemble. Do you think this would work for the re-enacting crowd?
Hmmm well in my experiences working with reinactors, they don’t like spending a lot on the guns, which is why they settle for used pedersoli’s and Indian made guns over custom muskets by the rifle shoppe. Any used Pedersoli I’ve sold to them i usually have purchased used at a bargain and sold for just what they could afford.
I’m an accountant by trade, the assembly cost of a brown Bess is pretty high in terms of raw materials. It’s a very large gun there’s no way to sugar coat it.
The cost of the steel, the machining of the barrel and lock, stock etc. I think 1500 is on the lower end of what you could reasonable be in a cost benefit analysis.
Track of the Wolf recently has terminated the production of their Bess kit which was priced around 1400 for a parts set that was not ready to assemble, I’ve assembled two of those, with the locks being from a casted parts set, not the new assembled lock they were selling before covid.
I greatly respect your desire for authenticity, however i do think there needs to be a compromise with a gun such as a brown Bess.
Dave suggested that one pattern of the two most advanced patterns the P1756 and the P1769 second model, both are very similar.
I might suggest making smaller scale versions of both (but not as small as a Pedersoli) as the reinactor’s likely would not mind at all. For example coach and harness made a P1756 that was accurate to the reinactors but inaccurate to a Bess aficionado. This gun today to produce would probably be equal to the Pedersoli cost priced around 1500-1900.
However the Pedersoli in kit form is only 1100 at Dixie Gun Works. I can’t see a a similar kit going for much more with a longer 46” barrel.
Some of those bicentennial coach and harness guns were very nice, stocked in English walnut most were not very nice though.