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While I am yet to play it, I would imagine Osprey's Dracula's America meets most, if not all, of your criteria. It is admittedly, as the name implies, supernaturally-themed, but I understand those elements can be readily ignored if required.
* One last thought: have you ever taken a look at Deadlands? Or its offshoot, Savage Worlds? The second isn't a dedicated Western set, but the rules engine is superb and could easily handle Wild West action.So there you go!
I’ve moved from Legends of the Old West to DMH to Gunfighter’s Ball, which is now my preferred rules set. GFB does not meet your criteria because it really doesn’t have a true campaign system built into the game. It has an experience system, where characters can gain in experience by surviving and being on the winning side of a scenario.Characters can be customized. In the rule book, there are Abilities and Quirks that can be assigned to characters. You can also use the Pistoleer deck to customize the characters in the same way, if you want to do it randomly. Otherwise, the major differences are in how many actions you assign to the characters on a side.And I’m going to have to disagree with the OP about the figures from Knuckleduster. I’ve had figures from DMH, from reaper, from Old Glory, from Foundry, and (IMO) the figures from Knuckleduster are the best figures on the market today.In closing, I have had more fun on a game by game basis with GFB than any other rules set I’ve tried. But based on the criteria that you have laid out, you may be best served by trying to find copies of Legends of the Old West. It ticks off most of the check marks you have laid out, but we found to it to be a bit dry.