First of all, If you are worried about protection from a front end collision stop reading right now. The way i figure, if I crash the car hard enough to cave all this in, Then I would have been toast anyway. NOW on to the thread

I purchased my support from a fellow member, and when I got it I put it on a digital scale and came up with a weight of 11lbs 5.3oz which is close to what they advertise, they say its around 10 lbs. I was curious if I could remove some weight from it and here is what I came up with, I started drilling holes, and then ended up slotting it. I WANTED TO KEEP IT STRONG ENOUGH TO DO THE JOB OF SUPPORTING MY BUMPER, AND AM NOT MOUNTING ANYTHING TO THE SUPPORT, I did not go to the extreme of removing too much from the piece. When installed I grabbed this support and lifted and shook, and it aint moving, the whole car rocked on my stands.The final weight of this support as it is now is 6lbs 15.3oz so I whittled almost 5lbs out of it, but ended up getting more weight off the front than that. I ended up drilling out the spot welds and removing my frame horns and welding the support to the frame rails,(like I said it is not going anywhere) It moved the support about 1/8 inch closer to the radiator core support, it still fits tight, I also removed the upper nose support and cover.
HERE are the weights done on an accurate digital scale
1. stock bumper support 21lbs 13oz (98 trans am)
2.upper core support and cover and frame horns 5lbs 2oz
So what I have total is almost 27lbs and my bumper support coming in at almost 7 has really eliminated a hair over 20lbs off the nose of the car, I have quite a bit of time in the support, it was alot of work, and I dont think I would do it again to be honest, woulda been easier with a plasma cutter. I still gotta mount the fog lights (this is now a million times easier) here are some pics, let me know what you think
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I like it

 

dam thats nice, looks like alot of work,

if my bumper ever starts sagging, ill get one, but ill also cut off the fog light supports

-brandon

 

Looks good but time consuming. We could make them a lot lighter but chose to make them the way they are to pass NHRA tech as a fuel cell enclosure.

 

Hey Steve how much extra would you charge to take that extra weight off for us guys not planning to use it as a fuel cell enclosure?

 

Too much. That is hours of cutting. At 60.00 per hour shop rate, ya all would have a stroke.

 

Now thats alot of work right there. Great job though you got that weight down.

 

There's probably 30 hours in that thing! I get the point though... nice work.

When I had one of these on my car I did remove all the top plastic pieces, there's no need to keep that there at all, as the little leg's do their job of holding the bumper completely in place. Anyone that hasn't removed that and put this support in is just lugging a couple lbs around that aren't needed at all.

The frame horn plates, I was going to cut back on mine before I sold it, we're cutting and redoing the whole thing and something very similar is going to get built into my car, so I didn't need it anymore.

 

I wonder if it gets to the point where if a NON NHRA certified Aluminum Version can be made. I am sure there is a market for it. I bet the strength difference probably wont be much different.

 

Thanks fellas, and it was alot of work, once I started though I didnt want to stop, you know how that goes... I have around 10-12 hours in it, Alot of time with a die grinder and carbide burr,,But now everyone has an Idea of what can be done, It could be even lighter I just didnt want to get stupid with it.

 

Cool, I like.

 

Very nice work.

 

Guess i'm missing the point. If your not using the burkhart bumper support for either a fuel cell or crash bar, then why would you spend the money on the piece? The only thing your doing with it is support the bumper cover? Then for about $20 you could make little metal brackets to support it.... I must be missing something.

 

Woooowwwww!

 

Is it necessary to retain that one last plastic shroud you still have?