> I don't see your alternative scenario as plausible
Valid.
That doesn't follow. If those were unmanned test flights pushing the vehicle limits you can't just assume they would have gone as they actually did.
As far as the launch to orbit, which was the flight phase when Challenger was lost, every Shuttle flight pushed the vehicle to its limits. That was unavoidable. There was no way to do a launch that was any more stressful than the actual launches were.