This has really bothered me so after some in-depth searching this is what I found on the topic of Conversion Cylinders.
Many people claim, "If you modify the frame, it's now a regulated firearm". I can find nothing about this on the ATF webpage.
What I did find on the ATF site was,
Federal definition (from GCA'68) of an antique firearm:
(16) The term antique firearm means
(A) any firearm (including any firearm with a matchlock, flintlock, percussion cap, or similar type of ignition system) manufactured in or before 1898; or
(B) any replica of any firearm described in subparagraph (A) if such replica
(i) is not designed or redesigned for using rimfire or conventional centerfire fixed ammunition, or
(ii) uses rimfire or conventional centerfire fixed ammunition which is no longer manufactured in the United States and which is not readily available in the ordinary channels of commercial trade; or
(C) any muzzle loading rifle, muzzle loading shotgun, or muzzle loading pistol, which is designed to use black powder, or a black powder substitute, and which cannot use fixed ammunition. For purposes of this subparagraph, the term antique firearm shall not include any weapon which incorporates a firearm frame or receiver, any firearm which is converted into a muzzle loading weapon, or any muzzle loading weapon which can be readily converted to fire fixed ammunition by replacing the barrel, bolt, breechblock, or any combination thereof.
I'm not a lawyer, but would take this as meaning if a Conversion Cylinder is installed on a Percussion Revolver, the said
Revolver would be classified as an FFL Regulated Firearm. It makes no statement about cutting a port in the frame, is does say
"designed or redesigned for using rimfire or conventional centerfire fixed ammunition", or "readily converted to fire fixed ammunition".
I did find a forum with the Old Kirst Paperwork pictured, which does state,
"Permanent alteration to the frame of a percussion revolver, to accommodate cartridge use, will re-classify that revolver to a firearm and as such must be transacted as a firearm thereafter".
Personally I think Kirst placed this statement to cover their backsides, as I can not find anything on the ATF site.
I looked over the literature which came with my Howell Cylinder & it states about the same as the Kirst.
The ATF definition includes "uses rimfire or conventional centerfire fixed ammunition which is no longer manufactured in the United States and which is not readily available in the ordinary channels of commercial trade", which I can find no such list.
https://www.atf.gov/firearms/firearms-guides-importation-verification-firearms-ammunition-gun-control-act-definitions-0https://www.atf.gov/firearms/docs/guide/atf-guidebook-importation-verification-firearms-ammunition-and-implements-war/downloadI must ad, I found a forum where a Gun Shop Owner had quit selling Black Powder Revolvers because he had gotten Nabbed for shipping a Percussion Revolver and a Conversion Cylinder in the same package without filing as an FFL Regulated Firearm.