I seem to have neglected to update this thread with the *real* weight. I found that it was closer to 150lbs (including my toolbag and foot air pump, bike lock/cable, and a pound of bungee cords I keep in the cargo pods).
So I put it on a diet, and have posted a couple times on the project blog about the results and potential weight loss candidates.
First:
http://electricle.blogspot.com/2009/09/first-day-of-diet-bike-is-starving.html
has pics of some of the changes.
Most recently:
http://electricle.blogspot.com/2009/09/diet-continues-decisions-decisions.html
I'm still trying to think of good weight reductions I can safely do, but there's not a lot yet.
* The frame mods already done took off perhaps 3-5 pounds.
* I might get a half a pound off by going to the single-cable multi-conductor thin-gauge wire for all the bike lighting and sensors and stuff, removing that scooter harness.
* I'll probably gain an ounce or two going to the all-LED lighting for the turn signals/marker lights, but I'll lose at least a pound by removing the other lighting system that was on the DayGlo Avenger (which I'd like to put back on it).
* The cargo pods and their attachment frame are maybe 15-20 pounds, empty. Part of that frame (the front half of the square tubing) is also the seat mount, though, so doesn't count.
* The batteries alone are I think 51 pounds. I'd have to go to something like A123 cells to get enough power in a lighter package that wouldn't be damaged by what I use it for.
* The difference between the 4 pole motor about to go on and the heat-damaged 2 pole motor about to come off is more weight added than I took off with those frame modifications.
* The front fork can lose around 5 pounds, maybe less, if I go to the non-shock fork. I'll gain at least two of that back if I add the headtube shock later.
* The steel front cranks are maybe 2 or 3 pounds heavier than aluminum ones would be (if I had any to spare for it).
* Can't get the seat any lighter.
* Handlebars are as light as they'll get for the shape I need, unless I could get some modern ones custom-made out of thinner but stronger tubing (or get lucky and find some scrapped like I did these).
* Those little white baskets that held the batteries before could take off a pound or so, but they will actually hold my backpack or something else, bungeed between them and the bottom of the seat, should I take the cargo pods off for any reason.
* There's nothing else I think I can safely remove from the bike frames themselves.
* The 26" wheel with wide steel rim is probably a couple of pounds more than a 24"; since I only really went to 26 because I had a lower-rolling resistance tire for 26 but not 24, I can go back to 24 once the tires arrive from All Electronics.
* The toolkit could probably be slimmed down a couple of pounds if I could standardize all the fasteners on the bike, so that any emergency roadside work doesn't require the large assortment of tools and driver bits that I carry right now.