Interesting Thread. I think the wax-casting would be at least worth looking into. I have an 1860 Army and 1851 Navy that both have taller front sights which I got years ago from Kenny Howell (of conversion fame). Kenny said they are the same ones he adds to the conversions and are set to be dead on at 25 yards. At least then he was always so busy it took me a year just to get two front sights. But, along with an 11 degree cut on the forcing cone and a 3-lb. trigger job, they basically shoot where you point the gun. They are so much more accurate when shooting off hand at 7,15, and 25-yards. I have never tried them at 50 yards. Will leave that to the more serious, dedicated target shooters - which are probably using mostly Remingtons. LOL Speaking of which, I once saw an 1851 Navy that used a taller front sight from a Remington revolving RIFLE. It actually looked pretty good. I've heard that the taller front sights used on the Italian factory conversions and open tops are set for 50-yards. But I can't confirm this.
Here's a couple pics of another 1860 Army I have. In addition to the trigger and forcing cone jobs it has a dovetailed taller front sight made from a drawing I sent to Jim Stroh (of custom 45 Auto fame). Sorry for the poor photos.
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An interesting thing to note is the height of the front sight on original Colt Peacemakers.
Rick