Refer to photo 7 for the parts layout.
The padding for the shoulder strap is actually a laminate of 10 mm thick
EWA (open-cell) foam (and yes, it's the white pad you see in the photos)
and 2 mm thick closed-cell foam (yellow), which is stiffer and denser.
Remember to cut the components for the shoulder strap in mirror image of
one another (L and R portions). Cut the pads according to figure 7 and
laminate the corresponding pieces together with quick drying contact cement
or any other appropriate adhesive. Let it dry completely (refer to photo
8; it is the laminated, yellow R shoulder pad at the rear portion of the
Cut the shoulder pad sleeve from
two types of material (figure 8). The inner side (the fabric next to your
body upon shouldering the pack) is cut from 210d coated nylon while the
other side (where the violet strap is attached is cut from 400d honeycomb
fabric. Tip: cut the outer side according to the pattern while for the
inner side, cut a big enough fabric panel where the outline of the former
Sew violet strap onto outer side
(4ood honeycomb) of shoulder strap sleeve according to photo 9 (at the
straight end area only). Assemble and sew sternum strap adjusters (also
shown in the same photo).
Sew the sleeves with the corresponding
panels together inside out. Sew 3/8" from then add an additional (reinforcement)
stitch line about 1/8" from the edge parallel to the previous stitching.
Afterwards cut off excess (inside) fabric along the outline of the outside
fabric of sleeve (photo 8).
Turn sleeve inside out. Viola! Now
you're ready to insert the pad laminate with the stiff side (closed-cell
foam) of the pad adjacent with the honeycomb side of the fabric sleeve.
But first, stitch the rounded end of the sleeve (photo 10) to form the
flap where the LL buckle will be attached.
Insert pad into sleeve. It may help
if you wet the pad first lightly with water to make insertion easier. Make
sure pad is inserted as far as it can go inside. Then sew the sleeve end
(open end) shut.
Stitch the violet strap at the middle
section of the pad (photo 10; it is the lower, semi-finished shoulder strap).
And yes, you have to stitch through the pad. A high clearance (presser
foot) sewing machine is ideal for this. Go slow and be careful so that
the needle is not over bent while stitching or you'll knock the "timing"
off .Tip: you may use your hand in turning the flywheel (manual override)
instead of using the (foot pedal) motor to power the stitching.
To finish the shoulder strap, insert
the sternum strap adjuster and then the LL buckle. Stitch the then doubled
back violet strap at the "flap" end. Reinforce your stitches by making
several passes at one line.
Sew the top ends of the shoulder
straps as shown in figure 9. Reinforce stitching by sewing in a crossed
box pattern (photo 11, although the stitching is more visible at photo
12 which shows the wrong side of the back panel). Ditto for the grab loop.
Then sew the 1 1/2" x 12" nylon webbing over what you have sewn (photo
12 and 13 for visual guidance).