After rereading the large post.

Is it an option to use alineas next time? Makes it a tad more easy to read.

On the ali baseplate. 5mm ali = 12mm HDPE in weight. 5 mm Ali bends, 10mm HDPE flexes.

Upgrade to LiPo, easy weight, saves money, and is the new standard. LiFePo4 is fine too, and has the advantage of being allowed to be recharged in the robot.

The wheels are acting up? How do they act up? The only thing I can see is lack of grip by the compound of the tyre used.
That seems also the issue with the wheels of Hardwired. I'm going to look into that, as several other machines use the same tyre.

The scoop. It was ment to be active, that's why there are axles in there. Making it heavier than needed. Nothing an anglegrinder and a welder can't solve tough. For a passive scoop you want one solid back/mounting plate.

More axes... if I find the time...