It doesn't get much better then this:

http://pinside.com/pinball/forum/topic/vids-guide-to-upgradingrebuilding-flippers

My tip is to change out the bushings too.

edit: I didn't read your whole post. I see you got the bushings.

bushings are usually the biggest issue. That and making sure it is aligned right. The vid thread is great! good luck

The white plastic bushings had screws and nuts holding them to the flipper baseplate. Williams usually put Loctite on the screw threads to keep the nuts from working loose.

I'll chime in as well on the bushings. They are often overlooked during a rebuild and are often cracked or worn to the point where there is too much wobble/play with the flipper shaft. Like KenLayton indicates, the bushings are usually held in on Williams games with screws and locktite. Go easy removing those, as you will want to reuse those. Alternately, there is room on the playfield side of the base plate for some low profile nuts/lock washers if you use some longer screws.

Just remember when you put the flippers back in, you are REALLY going to have to CRANK that pawl down to make sure the flipper doesn't move after a couple games.
It happened to me the first time, it just seems like you're tightening them until they are aboot to explode! But that is the way it's done.
Good Luck!

Any major differences when rebuilding Stern Flippers?

Not from my RBION I didn't really notice anything diff'rent.

F*&^king tight

Don't forget to clean your cabinet flipper switches when doing a rebuild. HS uses the high voltage series wound coils and the tungsten flipper switches get a lot of arcing and some pitting. Use a piece of emery cloth to clean the cabinet switches.

If the contact are gold plated ( low voltage ) DO NOT use anything abrasive on the contacts. A paper business card works well. The cabinet switches on HS are tungsten and pretty tough. Inspect and clean when doing the flipper rebuild. Switches are best adjusted for a wiping action when depressed.

If you remove the wires from the coils make absolute sure that you put them back correctly! Take pictures and notes! If the coils are fine best to not remove them at all, leave the wires on them and maybe tape or zip tie to the playfield somehow while you clean everything. Don't know how many threads I have seen where someone rewired them wrong and then caused board damage when they turned the machine back on.

Its easiest to snip the wire off and leave it attached to the coil with a slight piece of the insulation on the wire. Very simple to look and and match the color back up with the new coil.

this is your best friend if anything is stubborn untightening: http://www.amazon.com/gp/product/B000KKCQUW/ref=as_li_ss_tl

Also great advice, should have added that. I try and not remove them at all if they are still good, but when you do remove them that is a great tip.

Before you do anything make sure to take a bunch of pictures of your current flippers in the machine so you have a reference point once you start your rebuild.

I take the easy way.....pop in whole pre built assemblies from pinball life. 2 wires to solder and all is new

Coil lugs / wires on the opposite end ( away ) from the coil stops.
Less vibration and hammering to the lug wires.

This is my number one rule whenever I do any pinball repair.