Have you looked into a composite material for this bar of yours? From what I've read they have good strength/weight ratios and actually hold up to repeated stresses better too. Not much of an answer to your question but this is an interesting article on materials science in bicycles... http://www.calfeedesign.com/twp.pdf Also, if the bar in question is over-engineered (which is the assumption, since you want to drill into it and reduce the safety factor), why not replace it with a bar with a thinner wall thickness? -Dal ----- Original Message ----- From: Roman Black To: Sent: Monday, October 15, 2001 1:33 PM Subject: Re: [EE]: Drilling a square tube?? > Thanks Andy, everyone is already on a diet! :o) > > But motorcycle weight is like financial planning, > every few grams seems totally stupid by itself > but when added up at the end of the day makes a > major and important change in the balance of > performance. Liposuction? Maybe trimming some extraneous fingers and toes? How hard-core are you? :') -- http://www.piclist.com hint: The list server can filter out subtopics (like ads or off topics) for you. See http://www.piclist.com/#topics