Im not sure about going to 22 gauge wire due to the length of the runs but I can see how you could drop over a pound off from the plane. Under 40 is a nice weight for a plane this size. Big difference from my 150cc AW300 I had.
If I remember correctly my H9 Sukhoi with full exhaust is just over 40lbs.
I tend to ramble... here's the math I was thinking of:
12oz - DA vs 3W (guesstimate)
40z - 5cell Nicad pack I have taped to the tail (also guesstimate)
4oz - Pilot (might be 5oz installed)
2oz - sanding down the motor spacer (I can definitely do that, I've done it before, I could probably take 4oz off of it safely)
2oz - 22g vs 20g wire (I weighed 22g vs 24g on my Sukhoi and it was 3oz, I believe, I wrote it down somewhere)
1-1/2lbs total
Just totally guessing on a real accurate weight like I used to get on my old scale... I think you're right, our H9 Suks with DA-170 on pipes are 40 lbs. They just "feel" that weight carrying them around compared to my old 37-38 lbs 118" planes. They also fly lighter than all but a couple of my old planes (those two planes, an FMG and a Dalton, were actually too light for me... super light planes are very safe and docile, but they kite around and you have to wait on them... which is... boring. haha). And, I educated guess that my AW Yak55m is 40 lbs with 3W-170 and stock mufflers (although my bathroom scale says basically 38-39 without the nicad pack). So, I educated guess that with a DA, stock mufflers, no pilot, and 22g extensions it would actually weigh 38.5 lbs. Anyway, it flies good. haha BTW, I chose to use the 3W because I wanted that torque-y grunt-y hovering power... and in that regard the CS (even brand new and tight) did not disappoint.
