It was quickly decided that a new pistol would need to be designed in order to fully take advantage of the novel alloy. After much research and development, Colt's engineers theorized that if a stepped, or "rebated" cylinder was designed a large caliber could be combined with a small frame to make a new Army .44 caliber revolver that was a similar size and weight to the Navy .36 caliber revolvers then in production. Because Colt's new steel also negated the need for a beefy octagonal barrel, the new barrel was thinned out and turned completely round. The smaller frame, large caliber, pistol performed perfectly. This pistol would eventually become one of Colt's most successful models.
I thoroughly enjoyed your post to this thread, but I would like to add a few items, sir.
The Colt 1860 Army .44, in the first year or so of production, had a full-fluted rebated cylinder to reduce the weight of it so as to be similar in weight to the 1851 (and later) 1861 Navy .36 cylinders. Even with the "silver spring steel" it was easily overcharged with powder and many did not pass proof tests at the factory, as well as soldiers overcharging the cylinder in the field, and many cylinders blew up, usually at the front half of the chamber. Colt was relegated to discontinue the fluting and produce a round rebated cylinder to compensate for this, and that added weight to the 1860 Army.
The 1851 Navy .36 octagonal barrel was in vogue for that pistol for the duration of its manufacture, purely for aesthetic purposes, as the Colt Pocket Navy .36 had an octagonal barrel from its inception in 1865 until end of production, as well as the 1851 Navy. The same is true for the Navy squareback trigger guard on the 1st and 2nd Models, both continued from the 1848/1849 Pocket .31 pistols. It had nothing to do with the strength of the barrel steel. A part octagonal/part round barrel was cheaper and more easily produced like the 1848 Dragoon Models, and that is evident with the Confederate Griswold & Gunnison and Leech & Rigdon/Rigdon & Ansley revolvers which served well without the new steel.
The 1860 Army and 1861 Navy had round barrels with a curved barrel lug which was actually larger than the 1851 Navy because it had to incorporate the then new ratchet "creeping" style load lever rammer which was completely different than the 1851 Navy. That added weight. The early 1860 Army production guns had a Navy size grip frame and a 7.5" barrel. That was changed to a longer grip frame to compensate for the increased recoil and the barrel length was increased to 8". That added weight.
I do not have the pleasure nor the financial means to compare original guns, but modern replicas serve well for comparison. The 1860 Army is a larger, heavier gun than either the 1851 Navy or the 1861 Navy, but not as large as any of the 4 models of Dragoons produced by Colt, and his intention with the 1860 Army was to produce a belt holster pistol in .44, not another horse holster pistol in .44.
Pietta Leech & Rigdon .36
Armi San Marco 1860 Army .44
Regards,
Jim