Glad I could be of help! I think your idea of machining the tubes is the correct approach. The pivot points (steering knuckles) will be under a lot of stress. Machined alum or brass would be better for tubular parts.
I use teflon cores in any though holes etc. It works great, the metal will not stick to it, and usually no re-drilling is required.
I haven't tried recyling RTV into a new mold - but that sounds like a great idea!

Thanks I will consider that on my next mold.
Bob