I hatch my own meat birds out of Australorp, RIR, BO, EE, BR and some leghorns. They are not too terribly bad. Brahma X were more bones than anything but tasted great at 20 weeks. I am with you after a horrible hatchery experience. For now I will continue hatching out of my own flocks even if I yield less meat. Saves the hassle of quarantining the birds because of some weird infectious disease.
I love the idea with the early Leghorn processing. That sounds terrific and cost effective. Good luck!

