Need help with replacing worn gun parts

[Mean Matt McCord]

Pards, I must come to you once again, hat in hand, with another of my world famous stupid questions.

I bought some replacement base pins and base pin bushings for my pistols. On one of the cylinders, the old bushing slides right out, but the new one will not go in without forcing the garbage out of it, and I'm scared as you-know-what to try that. On the other cylinder, it's gonna take some effort to remove the old bushing.

What are some of your recommendations on how to do this? As I have said before, I am no gunsmith. Thanks.

[jiminy criquet]

I would guess that the bushings (like other gun parts) are made to be hand fitted to each gun, as the allowable tolerances vary.  Not being a professional gunsmith myself....only an amateur (although I did stay at a Holiday Inn Express once), I personally would sand down the bushing(s) until they fit.
As for the old pin/bushing that's still in the gun, (not knowing what pistol you're referring to) I would be looking to drift it out with some type of pin punch or wood dowel, taking care not to damage anything.  (I'm a big believer of using --multiple layers of-- blue masking tape and/or pvc tape to mask off stuff to help prevent damage.  You may scuff up the tape, but at least you don't bugger up the finish of the gun.)

[Malachi Thorne]

Good Afternoon, Mean Matt;

The simplest (and one least likely to damage parts) way to remove the old bushing would be to use even and direct downard pressure on the bushing, while securely holding the cylinder so it cannot move sideways.  If you have a drill-press handy, you can accomplish this as follows:

Secure the cylinder in a drill press vise with a few scraps of wood between the faces of the vise and the cylinder.  This will keep the cylinder from getting scratched.  Make sure that the bushing is facing down and that the jaws and base of the vise allow the bushing to fall unobstructed from the cylinder.  Most drill presses will have a center-hole in their tables large enough to accomodate this.  If you want to keep the old bushing reasonably intact, mount a plastic bag or somesuch to the bottom of the drill press table under the hole.

Get a brass or aluminum rod, slightly smaller in diameter than the bushing you are trying to push out.  Cut it off straight and clean (if it doesn't come that way already) and mount it into the jaws of the chuck.

Put the vise under the chuck, and apply even pressure to the quill-feed of the drill press.  The bushing should come out relatively easy.

Note:  The bushing will likely have a collar on it.  Make sure the collar is pointing down when using the drill press to remove it.

While you could use emery paper or somesuch to turn the new collar down to the appropriate size, you risk running it out of round, which would likely keep the newly bushed cylinder from accurately lining up properly on all six with the barrel.  If the new bushings are so large they will not fit the cylinders, take them to a gunsmith or a machine shop with centerless grinding capabilities, along with the cylinders they are meant to fit, and have a pro turn them down for you.  No sense messing up your guns by trying to save a little money on quality machine work here.

I have the honor to remain,

Your Obedient Servant,

Bvt. Captain Malachi Thorne