I think TC and Lyman both make an excellant rifles for what they are. Neither are entirely historically accurate as a "Hawkins" but in terms of workmanship, quality, accuracy, they represent a value for the money. CVA's aren't bad either and can shoot quite well. I know one old timer who used a CVA and out shot folks with modern custom blackpowder rifles.
A great shooter is a cheap $45 kit gun from the now defunct Markwell Arms Co. It was an old kit which the gunshop couldn't sell so it was put on the "discount" table. It was probably made by the same Spanish subcontractor as for CVA. It shoots great and the stock (by some freak of accident) is very pretty burled walnut. Like the CVA it features that ugly brass band about midway down the barrel (it's suppose to represent a patch for a broken stock but was used to conceal that the stock is a two piece affair). That brass gives it a real modern "poor boy" look which will be cured by its removal and the affixing of a new "underrib" beneath the barrel. Of course the barrel will be refinished as a brown instead of its present blue (hey, I didn't know the difference back in '96).
For percussion, my personal favorite is an older Parker Hale Enfield 2 band musket. This is an English Parker Hale and not the later Italian ones marketed under that name. It's an excellant shooter at about 350 yards. That's something I wouldn't try with any roundball gun. Of course, the tradeoff is more lead per shot.
Bottom line is what do you want and expect? A cheap gun which isn't the prettiest can still shoot well and better than an authentic looking gun. Don't discount a used gun either but be sure to inspect the bore for erosion (lack of maintenance) and stock (cracks). Whatever you buy, take the time for load development and learn to shoot it well.
