I've always used around 90-100 grains of BP with my rifled muskets. There is no safety issue with these guns, the light military 60 grain service charge was arrived at for totally different reasons and concerns...back "in the day".
I have even fired my Zouave many times with 120 grains of fffg under a thick skirted 625 grain minnie. However, recoil was/is "excessive" as they say. My standard load with that humoungous minnie is 90 grains of ffg.
The 1861 has a very heavy octagon breech on it.
My ArmiSport 1861 is shooting good right now with the 440 grain REAL bullet, a Wonder-Wad, and 90 grains of T7. This is just a temporary load until I can get some more Swiss BP, and then I will probably go up to 100 grains and call it good. With the 90 grains of T7, recoil is still relatively mild.
My 440 REAL actually casts out to 456. With no skirt it is not load/powder charge sensitive, and also it is very short compared to the skirted minnies, which means it stabilizes better in the slow twists.
I would agree that the lower powder charges in the 70-80 grain range will work fine, especially with the heavy slugs. I just like to smack the bullet a little harder to fill the grooves, and flatten the trajectory a bit. I'm not sure why anyone would want to shoot the 60 grain service charge...that's an extremely light charge in a .58" bore. Also, deer and elk is the name of the game around here, so I want one load that will do both. Not worried about killing the deer "too dead", but I do want to be sure I'm hitting an elk, or large black bear good and hard.
Oh on blow-back, that just depends on how open the nipple is, some nipples have HUGE holes in them, and when you approach 100 grains the hammer will start blowing back. My Armi Sport's nipple has a very small
[url] hole...in[/url] fact so small that I enlarged it a tiny bit. I think most of the newer replicas use nipples of a good design...but some of the older ones I've seen the nipple is just a big open tube.
Rat