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If there were a way to make good percussion caps and a danger free powder I'd be looking into those as well.
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You can get a cap making tool for $45 at .22lr reloader, percussion caps are easy to make, but a bit tedious. You can also use their .22 primer compound for the primer.
http://sharpshooter-22lr-reloader.my...sion-cap-maker
For making black powder, you can get some potasium nitrate, sulfur, and charcoal, use the 75% Kno3, 15% charcoal, and 10% sulfur ratio, (you can simply use 75 grams Kno3, 15 grams charcoal, and 10 grams of sulfur) mix it in a rock tumbler for 8 hours with lead round balls, spritz some water on the powder, rub it through a piece of window screen onto a tray, let it dry and you've got your own black powder. Not dangerous at all.