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A bit of research on Google will give you the forces on each side, the terrain, lines of approach, and so on, for any major battle of the ACW. For major battles you can often find the strength of each brigade, sometimes even each regiment involved.
All you need to do is divide the units by the multiplier used in Black Powder. (I don't know it.) If Corps 1, Div 1, Bde 1 has a strength of 1,600, that can easily be translated into the right number of bases or figures for a Black Powder unit. Go through the whole OOB like that, making adjustments where needed to make the game units playable.
The history of the battle tells you what units come on where at what time.
Another approach I like, is to take a historical battle and play it out of its time zone. You could for instance take the Battle of Kadesh (1274 BC) and turn the forces into ACW. This is a good way of challenging players, because it reduces their ability to recognise the battle and know in advance the historical progression.
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239th Infantry Regiment (2.5K)
(2K+)
The Righteous, Space Marines (3.5K+)
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