I wanted to do a reasonable sized unit as well so for $400, Wheat's Tigers.
Most of the time these guys get represented on the table as Zouaves, but only 1 of the five companies were equipped as Zouaves -- and then only at the beginning of the war. The other companies were outfitted in "salt-and-pepper" weave trousers, red firemen's shirts and both fezzes (which they apparently left in camp) and straw hats. I really liked the idea of the straw hats, so that's what I did them with.
The figures are Redoubt with 'bare' heads and the straw hats are a mix of plastic and metal parts from Warlord's ECW range.
There's a bunch of riflemen, a sergeant, lieutenant, drummer and flag-bearer. All the riflemen are Zouaves (higher pluck than regulars); it turns out that in larger LotOW games, it simply gets too annoying trying to have different skill/pluck ratings within the units, so the recent additions are units with all the figures the same. It makes it a little more tricky to juggle the unit to fit the cost, but I think it's worth it for the better playability.