Lots of discussion on weight here, which is fitting. Makes me smile. I really enjoy following along.
We could probably get the Gila to 2 lbs.
The way to do it would be VX07 or cuben pack bag with no mesh pocket and no bottle pockets.
Sew the harness to the packbag. Strip harness of all 3D mesh, only one layer of thinner lighter foam, go to a 210D (or even -gasp- 70D) outer fabric. 3/4″ webbing.
Strip 3D mesh from belt, no PALS, one grommet not two on adjustment, lighter outer fabric. One layer of lighter foam.
The frame realistically is pretty light. Titanium would be heavier, 7075 tube would be lighter as would carbon, but either of those is much easier to crack or break. You may shave 1-3 oz but at a large cost and big reduction in durability. (I saw flat bar aluminum mentioned – cheaper than our frame, but also heavier. Round tube has a higher strength to weight ratio than most anything.)
I think those changes would probably get it there.
At this point we’re designing to hit a weight, not designing for what we want it to DO. This isn’t our core.
It’s about tradeoffs. I’d rather have bottle pockets, a mesh face pocket, a comfortable carry, and something that will hold up even if I do beat on it.
I talk with Kevin often about what I call the “rebound point”. I started off backpacking heavy, got lighter and lighter and lighter, then finally decided I was cold, wet, hungry, or uncomfortable and started adding things back to my pack.
I think most folks find this point. If 8-10 oz adds a ton of functionality, ease of use, and comfort…..why not? Anyway, that’s a glimpse of the philosophy, right or wrong.