If I want to copy my Bitcoin data directory, remove the wallet, and give to people so they dont have to spend days upgrading their new bitcoin install, do I need to be worried about any data in any files outside of the wallet.dat containing any important data, like addresses or private keys or anything else?
If so, what files should i not include in the copy?
You don't need to worry about anything, your private keys are kept, managed & encrypted in the selected wallet.dat directory only, unless
you've copied it to other places.