[Dick Linn]

If you are using PVC pipe anywhere, try using ABS instead. We had to replace our PVC pipe rollers with ABS. If we could have found the very thin (say 1/16") ABS drain or vent pipe, we would have used that. There is also electrical conduit that is a foamed core PVC which is quite a bit lighter.

Some of the electrical components and non-stress items can be held on with nylon fasteners.

Steel sprockets can be shaved down quite a bit if you have machining facilities. If not, ask a local community college that has machining courses.

If you are using the kit frame, there's ways you can cut out a lot where the frame rails and joining pieces overlap since it seems to be a bit overkill.

Depending on the nature of the joint, you may be able to use a smaller but stronger bolt. One year, we used 10-32 allen head cap screws to hold our entire frame together rather than 1/4 inch bolts. A good grade of 10-32 is about as strong as a crummy hardeware store 1/4 inch bolt made with soft steel. We prefer grade 5 and grade 8 fasteners. You might be able to have some joints in aluminum welded to reduce the weight of overlapping sections and bolts. You may be able to grind a bit off the tops of bolt heads.

If you are using a converor belt of some sort, perhaps you can punch holes in it. We used some 2 ft wide rubberized cloth conveyor belt, similar to what tou'd see at a grocery checkout but fairly thin. Tough stuff, but very heavy. We sharpened up the end of a piece of small diameter car exhaust tubing and pounded out about 250 holes, cookie-cutter style. Had to use soapy water to get it to cut cleanly, and sharpened often.