Is it possible to reduce the weight of the DS frame 30-50% by drilling a lot of holes in the frame tubing?

 

One of the mags had an article about this within the last year I believe. I wish I had more info than that but they claimed to get 50 pounds off the DS. They did drill holes in some part of the frame but it was a while ago and I cant remember. I know they were very strategic about where they drilled the holes.

 

Just keep drilling holes until the frame collapses, then put one back. Let us know how it works out.

 

Have you tried finding a welding shop that would build you a frame from Chromoly steel? I remeber talking with a guy about a year ago that would build any frame made from chromoly for about $1,500. I thought this was reasonable since frames from LSR, Leasgers, Gibson, Aerons are a lot more than that.
I would be very cautious with drilling holes in the frame and sub frame.

 

Areas I think you can save weight on the DS650
1. TVI aluminum swing arm the +4 is 17 lbs lighter than the stock one.
2. Remove front fenders and replace a-arms save about 12 pounds
3. Remove the fan -2 lbs
4. Titanium rear axle saves up to 17lbs
5. DuraBlue aluminum sprocket hub -50% over stock.
6. Aluminum front bumper and rear grab bar
7. Replace all bolts with titanium ones save a pound but spend about $500.00
8. Replace rear brake light wit LED light bar -1 lbs and look cool

Parts that could be made

Billet aluminum foot brake and shifter.
Aluminum tie rods.
Rumor has it that the 04 DS might have aluminum upper A-arms
Remove stock head light and oil tank and replace with new aluminum oil tank in same place.
Make new front spindle and hubs.
Make new sub-frame out of aluminum

 

and..

-shave rear fenders
-Put small RCI fuel cell on it....maybe like a 1 liter for one drag race-use hauler paddles
-struts instead of shocks
-an aluminum bearing carrier
-remove front brakes
-remove dash
-remove air box/ snorkels
-run .125 wheels for drag racing
-run a smaller chain

thats all i can think of....

dont drill holes in your frame scooby.....

 

wow with all these calculations what you guy's are saying is my bike could be made 55-60 lbs lighter than stock???[img]i/expressions/face-icon-small-shocked.gif[/img] Then what would happen if i removed the sub frame cut off all the unwanted trash. Replaced the batt. box with a alum moved all the elec gadgets farther forward. Ran triple buffs all around used a glycol lucos mixture instead of water removed all sprocket protectors. Cut out all excess wiring from wiring harness replaced the steering stem with a lighter unit. you think maybe 68.9 pounds[img]i/expressions/face-icon-small-happy.gif[/img][img]i/expressions/face-icon-small-wink.gif[/img]

 

A lot of weight is contained within the rider...I suggest the Subway diet....lol j/k

 

Ok, it's time for a custom titanium ds frame! One for dunning/trail riding and one for drag racing.

 

OUCH that weight thing hurt hoover[img]i/expressions/face-icon-small-wink.gif[/img]

And buttfungus i like your thinking[img]i/expressions/face-icon-small-happy.gif[/img]