So I finally got the final shape of the tvps I was happy with and went ahead and cut the tvps. Everything turned out pretty good, and the fit was good.
Mounted my template on two plates of alu. Cut out around the template markings, then cut the bulkhead screw holes w/ the press. The actual cutting went pretty fast on the band saw.
Also ordered some more parts as the monthly rc budget turns over. Decided I was going to just install a fixed rear end for now. Got mugen rear arms and hubs coming, as well as all the cvds. I'm thinking the steering is going to be good enough for for 2ws. Its going to be a pita to figure out the 4ws with the top arms to get the caster right, as well as room for shocks. Plus there was no way to get the rear steering inside the tvps, as well as have room for batts and electronics. The rear arms are the same size as the fronts, so I can easily swap them later as I get it worked out if I want to.
The other plus is I can have more power and speed. 4ws gets a bit unstable with higher speeds as even a strong servo in the rear has trouble holding the rear str rack solid @ neutral at high speeds. 40mph or so is about the max with the old setup before it got a bit wily.