My Challis order arrived today.
I used the bushing removal tool to remove and replace the Springfield "thin" bushings for Challis "Normal" bushings. I secured the tool per the directions, with a standard size grip screw. Running the rod out to the end, I applied light and then medium steady pressure, until I felt the bushing move slightly. Then it just twisted out. Rinse, repeat for the other three. I checked for staking (none seen), and evidence of thread locker (not that I can tell, see below?)
Replacement was very drama-free; just ensure the new bushings were square, and not cross threaded. They required a little coaxing to get past initial take up but threaded smoothly. I checked with Challis web site and torqued the bushings dry to a bit less than 25 in lbs, and the grip screws (Challis, flat head) to a bit less than 10 in lbs. I opted to purchase O-rings for both the bushing to grip interface and grip screw to grip interface.
I had tried the standard grips with the Springfield bushings, but the results were very unsatisfactory. Tightening the grip screws down, there was no support for the grip screw head; and especially if I ended up shooting the gun that way (so I didn't.) The Springfield bushings are only about 0.017" above the boss of the bushing to "catch" the grip material. When placed on the frame on the slim bushings, the normal grips moved around, quite a bit.
The standard Challis Hex drive bushings stand 0.070" above the boss. The new bushings interlock very well with the normal size grips; I would not use standard grips with slim bushings; at least the ones on this gun, that's for sure. Perhaps the Garrison bushings are specced to match the very thin wood grips it comes with? I dunno. Anyway, I am very pleased with the final result. The new full size grips are extremely secure on the bushing posts, and do not move (at all).
I really really really like this Challis tool, it is amazingly effective. Trigger reach is still fine; but there is obviously a lot more purchase on the gun at both the grip tape and grip texture lock into my hands.