There's a kit semi-auto pistol available over here
(assuming you like semi-auto's)! Otherwise, you'll have to go here
for a SAA "blueprint".
Personally, I want to make a "1858" framed revolver with cylinder chambers similar to those of a Walker (ie., @ 60 gr. capacity
), with the mechanicals from a Ruger Old Army (i.e., coil hand, hammer, trigger and bolt springs
Regarding the shell casting, here's
a webpage which outlines a novel approach of using drywall joint compound! I noticed that (at least for aluminum,) they only recommended a 'double-dip' coating (guess it helps the coating flake off by itself when the object is cast).