Does that bayonet slide right down the end of the barrel?

Particularly early on in the American Revolutionary War (AWI), as the ranks of militia farmers joined the Continental Army, they brought with them their smoothbore firelocks used for sustenance and protection.  Smoothbores (musket, fowler) were a requirement for joining the Army. As a backup weapon, 'hawks and knives were employed.  Also, plug bayonets were fairly easy to create and some had gunsmiths move back or remove or increase the height of the front sight, cut back the forestock, and have a spike bayonet with socket made.  There are existing examples of 18th century plug bayonets and bayonet modified fowlers.

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Getting into Rev war reenacting will find an appropriate firelock the biggest expense.  Proper attire would be next, along with sundry accoutrements required to create a soldier's army kit.  The source for an appropriate military musket will either be offshore built (current DGW pricing shows a completed 1777 Charleville at $1650 and 2nd Land Bess kit at $1375) or custom built (far more expensive by comparison).  I have had, and have sold off, these three Pedersoli muskets - 2nd Land Bess kit, Charleville 1763/1766 kit, St. Etienne 1777.

However, do consider going with a fowler.  The Kibler Fowler in either 20ga (.615 bore) or 16ga (.662 bore) will make a dandy militia fowler that'd be perfectly period correct  and sports a long 44" bbl.  And there will be huge bonuses - the current cost will be  $1390 (maple or cherry), the build is quite easy, the total weight will be less than 7 pounds as compared to 11-12 pounds for a Bess or Charlie, the cost of a plug bayonet is less than $75.

Equally important is that the completed firelock will be superior to any offshore musket - you will have an excellent traditional smoothbore for ball or shot, for hunting or target or plinking. 

NOW, one can wait for the forthcoming Kibler 1st Land Bess kit - I know I am! - and like all of Jim's kits I expect it will be nothing short of fabulous.  Considerations - it will be a perfect musket for either Redcoat or Patriot alike, it will fit any time period of the AWI since the 1st Land Bess was a 1756 creation, it will be an excellent shooter, but it will be in the 10-11 pound weight range, it will cost more (maybe a lot more) than the Kibler Fowler, and it may be offered as late as June 2026, if AWI 2026 reenacting is a goal.  However, I expect the Kibler Bess kit to be an easy build that could be accomplished in less than one day (you build kits completely as working firearms first, then disassemble for stock finishing) and 2 to 3 days to complete clear coating, stain on walnut can be optional.

Just built my 4th Kibler Fowler in 16ga, plain maple (mine did come with a bit of flame in the wood), added a plug bayonet and a simple sling (not really needed, but handy to have) out of herring bone webbing.  6lbs 6ozs sans any bayonet.  7lbs 5ozs with a plug bayonet and 77" total length.  A joy to carry and use!  (For the nit pickers, yes, I've since installed a brass flash guard - can't do reenacting without one!)

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....Now if I can just get the shooter to factor out of the equation. He needs a stern "talking-to".

That's relatively easy with a Lead Sled and a hefty weight (or similar manner of bolting down the gun).

Rob, I think that most casting machines utilize the bottom pour method and from what I have seen, they produce good quality projectiles.

IME with casting alloy 420-540 grain slicks for long distance BP PPB target guns, either cartridge or percussion - ladle is the usual choice for the best most well cast bullets of that type, where quality is far more important than quantity.  I don't see where most cast bullets are used or required for typical smokeless target applications and those are mostly relegated to the jacketed flavors.  Handgun bullets is where a quantity is needed and that would suit a bottom pour best. 

Rob, I think that most casting machines utilize the bottom pour method and from what I have seen, they produce good quality projectiles.