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Originally Posted by Tom Bishop
Sprockets are a great place to loose weight. We put eight 1" holes in each of our 4 48 tooth drive sprockets and lost about a pound each. Sprockets are hardened steel, and will be difficult to drill without a press or a mill. It might be that a team has a mobile shop at the regional that you could use. We also lost about a pound by drilling out the side holes of the kitbot frame to 7/16". You can do that with a hand drill and some good arm strength! Watch out though, the hand drill will tend to "grab" and torque the drill around, possibly smashing fingers against the table top. We used a 6" hole saw to drill out the top plate where we put the Robot controller. Any solid pieces of metal are good candidates for holing.
What regional are you attending? Maybe a team with a mobile shop can let you know if they will be at your regional and can help with what is likely to be a lot of work and reassembly, as well as other teams that could help. Good luck and I hope things turn out well for you. 
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There should be a First supplied machine shop in a trailer at the regionals Ask the First people where it's located, sometimes it's in an adjacent loading dock, sometimes it's outside, kind of depends on the space.