The Viability of Making a New Merwin Hulbert

[RedGreen]

Ok, so I'm stuck on Merwin Hulberts.
I would imagine that the originals were first cast and then machined and then finished for fit by hand.
I don't have a lathe or mill yet (working on it) but I do have a furnace that would hold enough to cast one at a time.
I can make a mold of my MH frame and barrel, I would think it wise to use forged steel for a cylinder. I know of a machine shop which will readily do a one off cylinder for $1400... which is a bit steep. Choice of calibers would be 44 Russian or 44 Special due to it's availability and ease of reloading.
The trick is to bore the cast barrel and then rifle it.
Any thoughts? From machinists or others?

[St. George]

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[Blair]

RedGreen,

All my experience with MH indicates they were forged, then machined. Not cast within the period.
I have also not found any reliable degree of interchangeability within most model types, especially within the large frame models. It does not seem to exist.
They are a unique firearm in many respect and worth exploring.
My best,
  Blair