Understood and I fully realize the issues with the game engine for a period of history this complex.
The other issue I recommend you think about is the "Hollywood History" perspective many of your customers will have, especially in the colonies. Generally, this period of history isn't as popular as the ACW or WWII, so familiarity is based on whatever is on the television or at the cinema. Thus everyone knows all British uniforms were red (with full apologies to the RA, RHA, Light Dragoons, Hussars, Oxford Blues, the 60th and 95th Foot), because that's what it had in Mel Gibson's The Patriot! Make the detail of your game too accurate and people get confused and word gets around.
Fortunately you folks have stuck with making sure the units function historically in your ACW games, and North v South is pretty simple uniform wise. My recommendation is you dig in your heels and never portray the former, but compromise on the latter.
As an example, if I were doing this game (not knowing squat about programing) I would make two cannon sprites, one single and one split trail and just color them differently by nationality. I would pick one flag for the Prussians and have everyone carry it, even though Prussian light infantry, hussars, lancers, Landwehr and all infantry regiments numbered 13 and above carried no flags at all. Then you can get away with putting ALL Landwehr in grey Letewkas, all Jaegers and Schutzen in dark green and so on. The most common flag seems to have been the black and white standard carried by the 2d East Prussian Infantry, so either their Kings or Regimental Color is the way I would go.
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If you have time in your busy day, check out page 3 of a review I did for wargamer.com on Empire: Total War at
http://wargamer.com/article/2688/pc-gam ... ive?page=3 . Just don't do what they did.
Otherwise I'll keep track of your progress and interject on occasion if I think it useful, fully willing to shut the hell up when told. Let me start by recommending a YouTube video you might want to watch given cavalry will have a much larger role in this game than anything you've done before. Its of the French Garde Republicaine executing a cavalry charge by the book, 1805 edition. Errol Flynn and Mel Gibson it ain't and you can find it at
http://www.youtube.com/watch?v=cOl4piWh2eA .
Given your other stuff, I am really, REALLY looking forward to this game.
Ciao, Colonel Bill