Very cool write up. I'm tossing the Idea around for an AI car next year as well. Your story has given me a bit of inspiration.
As to your vibration, I had a similar issue, and it ended up being the rear end was junk. Swapped to a new Speedway Engineering unit, new Currie third member, and no more high speed vibes. I know that is probably no what you want to hear, but at a minimum I'd check the rear axle for "trueness" and pic yourself up a second carrier to rebuild. Never hurts to have a spare set of gears around.
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