We find that using a drill to cut weight is not easy--it takes houndreds of holes in sheet to make a difference-unless it's small to begin with, you use a holesaw, or it's thick stuff (but then the whole thing is too heavy anyway). We used a saber saw to cut large triangles out of the drive plates- saving about a pound per plate. Our wings are similarly cut. We are now in the 120-125 range, so we are glad we did.
Many of you may have seen "wrench man", 449's logo. We have "person" made out of ~1" head wrenches, that weighs about 5 lbs. We hope to be able to add him to our robot (but only if we dont add any other weight for systems).
We did this last year, when a problem led to us re-designing the frame at houston. We weighed in
at:
http://www.manisbutareed.org/USFIRST2003/Houston/p4110029r.html
untill we had more time to add systems back.
Here is a team member w/buttons that have wrench man on them, arranged in the wrenchman shape:
http://www.manisbutareed.org/USFIRST2003/Houston/p4110005r.html