Has anyone done this compared to taking the bus? Is it too much of a hassle for what you save on price? I am not fond of curvey windy roads like some said about the bus. We will have a swiss rail pass but not eurail.
Travel by train will take longer, as you'll first have to travel from Tirano to Milano Centrale and then from there to Lugano. If you decide to make that trip, a Rail pass would probably not be cost effective. You'll be using Regionale trains, which are quite cheap anyway.
The bus from Tirano to Lugano does follow a somewhat "winding" path in some parts, but they tend to do the curvy parts slowly and they also stop for a coffee / WC break about half way.
and it is not so much a bus as a comfortable coach with huge windows and comfy chairs.