Buy a paperback first aid manual instead of hardbound
Reduce the size of scissors and tweezers in the first aid kit
Plastic, mouth-operated foghorns weigh mere ounces
A tiny hand-bearing compass can serve as the non-electric spare
Foil radar reflectors save great weight aloft
A deep reef in the main eliminates carrying a trysail
Tools. Extra hammers, a gigantic rig cutter, broken spare parts and stray bits often seem to accumulate here without trying. Don't scrimp, but eliminate all the clutter that gets tossed in. Consider a multipurpose screwdriver instead of a set of four.
Charts. The rules specify a set of non-electronic charts, a light list and plotting tools be on board. For most Category 4 races, one well-chosen paper chart should suffice while all the rest may be left ashore. Aluminum dividers can replace the big, decorative brass pair and a 5" square plastic protractor substitutes for 18" parallel rules at half the weight.
Category 4 ORC races allow either USCG Type III PFDs or comparable inflatables--both are lighter than the Type I lifejackets needed on offshore races. Multiply the weight savings times six crew.