TL;DR
Adam Savage set out to shave weight off a classic Emeco Navy chair by drilling thousands of precisely placed holes into its welded aluminum frame. What started as a quick experiment turned into a two-year obsession as he wrestled with CAD layouts, tooling challenges and the sheer tedium of punching out each hole without compromising strength.
In the end, the project became an unexpected deep dive into materials science and fabrication techniques—proving that even the simplest designs hide a ton of complexity once you start tinkering with them.
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