Glad - and relieved - that you got rid of the kit shrouds and deadeyes. I also agree completely about the vac-formed "sails." Whoever came up with the ideas of representing rope and canvas with such substances ought to be...well, never mind.
If you don't want to buy individual replacement deadeyes, you probably can get the plastic ones to work (though the plastic "rope" lanyards will never look as convincing as thread). My suggestion would be to slice off the plastic sheer poles, glue the halves of the deadeyes together quite firmly, seize the shrouds around them (just as you would if the deadeyes were made separately), and add the sheer pole later from either wire or plastic rod.
If you decide to replace the upper masts with wood, no experienced modeler will blame you. The plastic parts can be made to work; since this is a big model, they're just about big enough to support themselves and the rigging. But they'll never be as sturdy and rigid as wood ones.
Regarding hammock nettings - before you resort to metal mesh, try the local fabric store. Such places sell a wide variety of nylon mesh. Most of it is made in a hexagonal grid pattern that isn't appropriate, but if you look hard enough you'll find some that's made in a square pattern. I'd recommend ditching the plastic hammock netting stanchions and replacing them with wire. And check out some photos and drawings of real hammock nettings. Some modelers tend to assume that the mesh of the netting should be as fine as they can make it. In reality it's surprisingly coarse. The openings in it are at least three inches wide. That's 1/32" on the scale - pretty big as such things go.
I build one of these kits years ago and planked the decks with basswood. As I remember (don't trust my memory; this was a long time ago) the deck pieces of the big Revell
Constitution are supported by heavy pins projecting from the hull halves. The locators on the deck pieces (I think) consist of lttle pads, about 1/32" thick, that sit on those pins. If I remember right, I started out by shaving those pads off the bottoms of the deck pieces, thereby making the entire deck drop by 1/32" - which was the thickness of the basswood planks I used to cover it. Worked like a charm.
Basswood isn't a bad material for that job. (Its great virtue, from my standpoint as a starving college student, was its availability in appropriate sizes at the hobby shop.) Maple would be better. In my opinion, though, the best decking material of all is holly veneer. Its grain pattern is such that, with a little help from stain, it literally looks like miniature wood. And it's hard as a rock.
The "black glue" trick is one of several that people have come up with to represent deck caulking. It works all right - though it's kind of messy. My favorite technique for that purpose, though, is simply to rub each edge of each plank with a fairly soft pencil. That produces an extremely thin line that can't be eradicated by sanding, and is dark grey in color. (The caulking in an actual deck is no more black than the asphalt in a street.)
The question of the bell is an interesting one. Logic suggests that the ship must have had one. (The normal quota in those days would have been at least two - one by the binnacle and one on the forecastle.) Putting two and two together, my best guess is that the absence of a bell from the Revell kit can be traced back through the research process.
As I understand it, Revell used the plans that were drawn by George Campbell for the model the Smithsonian commissioned back in the late fifties or early sixties, in an effort to establish what the ship looked during the War of 1812. Campbell, in turn, relied heavily on the "Isaac Hull model," in the Peabody Museum (now called the Peabody-Essex Museum) in Salem, Massachusetts. I mentioned that model in an earlier post. It has extremely detailed rigging, but the workmanship and materials of the hull and deck furniture can most gently be described as folk-art-like and most accurately as downright crude. (The gun carriages, if I remember right, have no wheels, and each gun is held in place by an enormous nail with a projecting head.) My guess is that the bell got omitted from that model because the modeler had no idea how to make one, and that Campbell, being the extremely knowledgeable and conscientious researcher that he was, didn't want to speculate on it.
Since the Revell kit was first released (in 1965) a great deal of additional research into the
Constitution's appearance at various times in her career has been done. Two American wood kit companies, Model Shipways and Bluejacket, have issued kits that make great - and, I think, justified - claims of accuracy. It would be interesting to see what the plans of those kits have to say about bells.
Interesting stuff. Good luck.