Looking for material suggestion

I want to make a new pack bag for an old Kelty external frame pack. Should I be looking for Cordura , Ripstop or something else? Thanks

I'm not a DIY sewer, but people who are often get fabric from these guys (and they have a whole section on pack fabric): https://ripstopbytheroll.com/collections/pack-fabric

I checked out Ripstop by the roll. That is where I found Cordura and PU ripstop. I will probably try PU ripstop. Thanks.

The material Kelty used on the D4, Tioga, etc. is generically known as "pack cloth," and is about 7-8oz. per square yard, 400-450 denier, and PU coated. It wasn't a ripstop weave, and didn't need to be, since it's fairly heavy.

Something like this: https://www.seattlefabrics.com/60-400-D-Packcloth-Nylon-895--1050-linear-yard_p_48.html

I'd suggest the V46 polyester thread, also from Seattle Fabrics. Most home sewing machines won't handle the V69 well with coated fabrics. "Regular" polyester thread will work, too, with maybe some extra stitching for reinforcement in places.

You could use lighter fabric, though, like the 210d Robic ripstop from Ripstop By The Roll.

Other good sources are:

Outdoor Wilderness Fabrics https://www.owfinc.com/
Quest Outfitters https://www.questoutfitters.com/

Thanks Bill, I believe my pack is a D4 on the mountaineer frame. I will look into the links you provided.

I've been thinking about making another one for myself, and I've got my eye on the X-Pac.

The tag on my Vargo TiArc backpack indicates it's 70 denier ripstop nylon. I also have the newer Vargo ExoTi backpack. The tag doesn't indicate the fabric but I suspect it's the same.

I've made several internal-frame packs with 70d ripstop. It's not nearly as durable as the heavier fabric, but OK if you take care of it. On an external frame pack, I wonder if the 70d wouldn't wear quickly where the bag contacts the frame crosspieces.

On the Kelty D4 frame, the grommeted flaps that fasten to the frame would need to be reinforced, either with extra layers of fabric or maybe some thin webbing.

Regular grommets will work...I've made several packbags for external frames and had no problem (with heavier fabric.) Spur grommets were used on the Kelty, and are better, but the setting tool is expensive.