In Adv. 343, Chameleon Boy's not looking where he's going and flies into a bridge, breaking his shoulder. They say he'll be fine in a few weeks. Hello? I'm thinking he could just use his power to refuse his bones and be fine lickety split.
In Adv. 350, Superboy and Supergirl were discharged from the Legion and brainwashed because, once discharged "they might inadvertantly leave clues to our secret weapons, which their enemies might find and use against them." Um, so what was keeping them from doing that while they were active Legionnaires?