So the "shove it all into a plastic bag and clean up with shop vac" worked pretty well actually. I was a little concerned about jamming and whatnot because the amount of dust and debris is startling when you see it piled up on the cuts, but there was zero issues.
When finished, I took it outside, and used my mini shop vac to clean it all up. I was sure to still wear a respirator while cleaning. Tossed the bag in the trash, cleaned the router thoroughly, and then put it in another bag for next time and to keep any missed dust or fibers from getting anywhere.
Waiting on a quote from Xometry.com to see how much it'll cost to have them do it. At first glance, it may only cost me about 20 dollars more then it costs me now to do it myself for the entire chassis!
So with everything cut, it was time to get to business....
This was the OG Invader chassis. It's a scary sight seeing a car that was already running in the low 2's torn apart like this. But, you can see just how "hacked" this thing is. Good bit of trial and error, and massaging holes to make things fit and line up. I debated selling it, but I think it's going into a glass case as an "artifact". My team mate said I should set it back up with a Slash drivetrain just to have a "different" car, but man I really made a promise of "no new RC cars" after I finished Hissed Off.
I started assembly of the new chassis...
It's definitely cleaner, and considerably lighter than the OG. More on that weight difference(and other differences) at the end.
I started on the front piece first. Assembly indicated improvement over the Hissed Off cuts, but would need very minor tweaking for the final design on a couple of holes. I only need to very lightly massage them to get things bolted up. Next cut will be 100% spot on. I also note that the 4.5mm diameter holes for the M4's are very tight - but that's good - even though it's a little tedious getting them initially through the holes. The M3 holes at 3.5mm are far easier.
The transmission mounted perfectly. Whew. Nothing to do other than bolt it up.
Mounted up the shock towers and engine. Everything but the engine mount adjuster slot was perfect. The slot needed to be moved to the left 1mm, so I dremeled it, then updated my design. I had to work on my shock tower to allow it to bolt up to the transmission, greatly reducing rear chassis flex. I've since designed a new one that I'll print out for the ones I'm selling.
The completed chassis! Everything lined up nice. I didn't have to adjust even a single turnbuckle.
All body posts lined up correctly as well - and the body height was all still as before.
The car dropped a pretty significant .3 lbs of weight overall between the new chassis and wheelie bar. Invader weighs .9 lbs more than Hissed Off, largely due to big block engine, all steel gears/shafts, and aluminum beadlock front rims, as well as the parachute assembly. So approximately 20% heavier, but likely 50% (or more) more horsepower and torque. Note - if Hissed off wasn't using aluminum shock towers vs CF, the weight difference would be larger, but that car would not hook up for sure if any lighter.
My only issue for concern is that the chassis is decidedly springier than the OG one, and how that'll affect big block power transfer, etc, remains to be seen. I could, or redesign the coupler to have an extension back to the engine mount to eliminate that if needed, but it might not be necessary, and it might even help with traction for the chassis to absorb some of the force. Though, I think some people may prefer it not to have any flex, so I'll probably work on that.