The OP could easily cut that number down to almost nothing if he switched to dehydrated water and just make it as he needed it.



On a serious note at least more serious the OP seems to have the skills to manufacture and the inventive mind to go along with thinking big. I would encourage him to maybe even think more outside the box than he is though. He’s building on what is known and done with bicycle design and maybe he should be looking at something quite new and never done before. Starting with the bike and ending with the dual purpose cases. What if a frame came apart into many smaller parts with some new connection method that’s never been done like high tech tinker toys. And fit into some super light small cases that were water tight and made to attach to this knock down machine. Maybe water storage built into the cases and gear that fits in and around bike parts for shipping.