Same source engine as modern TF2? How does that work?
This could be simply be my ignorance of how these games are built, but if you can run beta code on top of the current source engine framework that would mean slightly less work.
Here's an example patch from 2009: http://store.steampowered.com/news/2825/
-Fixed explosive radius detection using an axially aligned box instead of a sphere
--Compensated by increasing the radius of grenades, pipes, and rockets to 50% of what they lost at the corners of the OBB
--Grenades/Pipes radius change: 132->159
--Rocket radius change: 121->146
This was a huge change to the mechanics of explosions so that they were more consistent. I would expect this to be part of the TF2 codebase rather than the source engine, does your version have this update?
Here's a complete list of patches if people want to start digging and asking questions: https://wiki.teamfortress.com/wiki/Patches