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What would happen if s swapped out the Alu chassis for say Nylon, kept the 4wd, the disc and the shrimech, got Lipols or LiFe/A123's and then covered the exterior with 2mm Ti? (we have a sheet of it at uni going spare (Titanium going spare!))
Ali to Nylon will be a good alternative but don't go too thick or the weight saving won't be that great. 12mm minimum would probably be my recommendation (15-16mm if possible). That should be plenty strong enough for your needs, although you'd still probably have to cut the triangles out of the Nylon bulkheads too. Going to some form of lithium batteries and thinner ti armour will also help save weight, although 2mm ti isn't invincible against the more powerful spinners. I can't say for sure if that would save you enough weight to keep 4WD and the sri-mech, but if you can alter the material densities in your CAD file and search around for some rough weight values of lithium packs, that should give you some idea of what the weight will be.