DESGINED is the critical word here. I would expect the engineers at SRAM are qualified for this task plus would have simulated on a computer as well as tested samples.andrew9 wrote: ↑Thu Jan 18, 2018 6:55 am
I'm surprised the cassette failed, it must be thinner than it appears in the photos. When you compare it to those SRAM cassettes that are very minimal, but still DESIGNEDfor abuse by heavy riders, I would have thought you would have been fine with your modifications.
The OP is in unknown territory - I don't think any of us know how much metal can be removed before failure. It's is always goingto be a risk, remove some metal, it works, remove some more, still works, remove a bit more and snap!! As long as the failure does not result in injury or death, then that way of working is fine - the critical parts are really the stem/bars as there is little chance of recovery if they fail and then brakes - I hopy you are using stell or Ti bolts for the 3 remaining holes on the rotors and no alloy bolts.