* Freakenstein (can't spell his actual name) gets ripped apart by the Commando Elite. Brick Bazooka has his lower half torn off. Both are repaired, Bazooka to full functionality. Why, then, does Nick Nitro "die" (for lack of a better word) when his legs are shredded? Freakenstein had to have been more damaged than him, they couldn't even give him both arms!
** Kinda FridgeBrilliance. The Gorgonites are a more primitive race, without as much medical skill, while the Commandos are military trained, and Bazooka was really just disassembled They put him back together, with tape to make sure he stayed together, much like a cast. Nick Nitro, on the other hand, was SHREDDED. His legs were destroyed, not just taken off. Think chainsaw vs car for damage. Of course, It's been years since I saw the film, so I might be wrong. But it was my favourite movie way back, and I watched it a LOT.
** They didn't want to turn him into what they viewed as a "hideous beast".
** If you believe what Chip Hazard said, The garbage disposal didn't just slice Nick's legs of but also cut through the Lithium Cell causing the battery acid to leak out. Sort of a toy's equivalent to bleeding to death.
* What happened to the other Major Chip Hazards that should logically have been in that truck?
** This also leads to some Fridge Horror - after all, what happened to any Gorgonites in that truck?
** The other Chip Hazards were probably left deactivated by the main baddie -- no point in confusing the chain of command. The Gorgonites? Fragged 'em all.
*** Or worse; All those weapons they show up with were initially just toys. Where would they have found a source of military grade parts to "upgrade" them?
*** Looked like mostly just stuff from the hardware section.