I helped a good friend build a lot of USPSA comp pistols, and we looked at a lot of comp designs, though most were for 38super and later 9x25 which provided more expanding gas to make the comps work... the bushing comps don't work..a threaded barrel is your best option, and if you look at Brownell's and other manufacturers a suitable barrel/comp can be put together for your project...there is a point of diminishing returns concerning reliability when the comp gets longer than 3 ports, unless suitably supported by a full length guide rod that helps keep the barrel from dropping... I'd keep the overall length to around 2" and with 3 holes around 3/8"... for a "one off" a 3/8" bullet exit hole (.375 - .356 = .019/2 = .009 clearance) is probably your best bet, but if you have access to a reamer that pilots in the barrel, then the tolerance can be tightened up a tad... you may want to machine a clearance on the rear of the comp for the bushing if you want to have a neat looking installation
a reverse loading recoil spring plug is the best option... remove the material at the rear of the spring tunnel in the slide, so the plug can be loaded from there... a captured spring system using a full length guide rod should be made... lock the slide back, mark the rod just in front of the bushing to drill a small hole in the rod so that a "L" shaped wire can be inserted, release the slide which will catch the wire... remove the slide and the recoil system can be removed, and then the barrel.. good luck