The new mount is currently 31g lighter. It should also be slightly more aero (because the light is in front of the headtube and the separate light mount is gone). I plan to remove a few more grams.
This used an offcut of aluminium U-channel which I had left over from a different project. The 1.6mm thick aluminium is more than strong enough - if you bought a new section of 1mm thick aluminium for a project like this, it should be OK. Also, my ideal would be a single countersunk 25mm M5 bolt which tensions the puck and the light directly, but I didn't have one to hand, so I used separate bolts for the light and for the computer puck. I also want to pitch the light down a few degrees by shaving some aluminium off the sides just behind the light's bolt. It should also be possible to taper the sides of the aluminium channel at the rear end. So there's a lot of scope to make further improvements if you want to spend more time & money on an out-front mount like this.
More photos here. Hopefully this inspires a few people to try improving their own out-front mounts!
