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#201237 - 06/27/18 05:39 AM New Pack Finished
Bill Kennedy Offline
member

Registered: 02/27/18
Posts: 105
Loc: Portland, Oregon
I finally finished my new pack. 25.5 ounces. I used pretty light materials, so durability could be an issue, but should be OK if I'm careful with it. I had the materials on hand except for the actual fabric, so it didn't cost too much to make. Like all DIY projects, I'm now thinking how I could have done it better smile

The details:

The light blue material is 2.2oz HEX70XL ripstop from Ripstop By The Roll (actual weight 2.73oz/sq. yd.). This material has a somewhat heavier coating than most similar material, which gives it a slightly rubbery feel and also makes it harder to pin. I don't think I'd use it again.

The black material is 200d coated nylon oxford (actual weight 2.95oz/sq. yd.)

The mesh is 2.6oz/sq. yd., which is pretty lightweight

The hipbelt and shoulder straps are 1/2" closed cell foam and the inside surfaces are a soft shell fabric.

The lumbar pad is a sandwich of 3/8" open cell foam, 3/8" closed cell foam, and .032" fiberglass (thin PC board material without the copper.) The fiberglass distributes the weight, as the bottom of the stays are directly behind the lumbar pad.

The back pad is 3/8" open cell foam and 1/8" closed cell foam. I used Carl Havens brand waterproof fabric adhesive to laminate the lumbar pad, back pad, and to glue the soft shell material to the foam (no longer available but 3M 77 adhesive is similar, I think.)

The stays are 0.1"x0.5" 7075-T6 aluminum. The regular aluminum from the hardware store bends too easily in the half inch width. The 7075 is springy and will flex quite a bit without bending. Harder to bend into shape, though.

There's a zippered pocket above the mesh panel on the front that's about 8" deep and runs the whole width of the pack. The pocketitself is internal, just the pack material folded over itself.

The lid pocket is 11.5"x8"x3" and will extend upward to accommodate the 8" silnylon extension collar (not shown in picture). The lid pocket only weighs 1.6oz., so I decided it was worth it.

Overall dimensions are 11.5" wide, 8" deep, and 23" tall, from the bottom to the top of the stays. These are rectangular dimensions, so when actually loaded, it bulges out slightly. I think the main pack is about 2500 cu. in. or 40 liters, not counting the extension collar.

Here's a link in case the picture isn't visible:

http://i350.photobucket.com/albums/q438/WilliiamGK/Blue%20pack_3%20views_zpsruzximul.jpg

_________________________
Always remember that you are absolutely unique, just like everybody else. -Margaret Mead

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#201238 - 06/27/18 07:17 AM Re: New Pack Finished [Re: Bill Kennedy]
Pika Online   content
member

Registered: 12/08/05
Posts: 1767
Loc: Rural Southeast Arizona
Really nice job Bill. Well thought out and excellent workmanship. I think the flat stays will be more comfortable than are the round ones I’ve used. Good job!!
_________________________
May I walk in beauty.

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#201244 - 06/27/18 01:07 PM Re: New Pack Finished [Re: Bill Kennedy]
4evrplan Offline
member

Registered: 01/16/13
Posts: 743
Loc: Nacogdoches, TX, USA
Looks really nice! Impressive build and features for the weight for sure.

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#201245 - 06/27/18 01:10 PM Re: New Pack Finished [Re: Bill Kennedy]
OregonMouse Offline
member

Registered: 02/03/06
Posts: 6561
Loc: Gateway to Columbia Gorge
Looks good! I would want side pockets (for water bottle, tent, fishing rod), but that's me, not you!

The trick with these lightweight materials is to handle the pack carefully, not plop it down any old place and especially not drag it. Also, if you regularly smash off-trail through slide alder, devil's club, and similar Cascades vegetation, the material may snag and rip. My pack from Six Moon Designs (discontinued in 2006, so no relation to their current offerings) has held up well in the 12 years I've had it (although I haven't been able to use it much the past 3 years). It's made of silnylon with a dyneema bottom. (It did require a little re-stitching after its first year, but SMD did that for free). It has flat aluminum stays very similar to yours, and, for me, is very supportive and comfortable.

I hope you have many good years with your new pack!
_________________________
May your trails be crooked, winding, lonesome, dangerous, leading to the most amazing view--E. Abbey

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#201248 - 06/27/18 02:27 PM Re: New Pack Finished [Re: Pika]
Bill Kennedy Offline
member

Registered: 02/27/18
Posts: 105
Loc: Portland, Oregon
Thanks. The pictures you sent were a big help. I almost used the aluminum rod but the 1/10" flat stays are a little lighter and I like the idea of the stays connecting more directly to the lumbar pad and the load lifter straps.
_________________________
Always remember that you are absolutely unique, just like everybody else. -Margaret Mead

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#201249 - 06/27/18 02:28 PM Re: New Pack Finished [Re: 4evrplan]
Bill Kennedy Offline
member

Registered: 02/27/18
Posts: 105
Loc: Portland, Oregon
Thank you. I was pretty pleased with the weight.
_________________________
Always remember that you are absolutely unique, just like everybody else. -Margaret Mead

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#201250 - 06/27/18 02:35 PM Re: New Pack Finished [Re: OregonMouse]
Bill Kennedy Offline
member

Registered: 02/27/18
Posts: 105
Loc: Portland, Oregon
There are side water bottle pockets. They just don't have anything in them, so they look kind of flat. They're plenty big for water bottles, though. You can see the casing for the elastic in the side view. I made them of the same blue material. Lighter than mesh...we'll see how they hold up. I did make openings in the corners for water to drain out. I suppose the diagonal compression straps above them could be used to hold something long like a fishing rod or tent poles.
_________________________
Always remember that you are absolutely unique, just like everybody else. -Margaret Mead

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#201255 - 06/28/18 12:21 PM Re: New Pack Finished [Re: Bill Kennedy]
PaHiker Offline
member

Registered: 02/12/15
Posts: 129
Loc: Western Pa, USA
Awesome! Feels great to get that first one under your belt, doesn't it? Made my first one a couple years ago, took it on a bp trip down the Grand Canyon. I was impressed by how well it handled, then found changes I wanted, which led to my second version. Been using that one for a couple years now, but have to admit I am thinking of more changes for a third version.

I love your color choices, and the finished pack looks real professional (mine definitely looks homemade). I would be interested in more on how you added a zipper. I had thought of that a couple times, but wasn't sure how to add a zipper. The ones I've found were of a size that didn't work with my pack.
_________________________
Life should not be a journey to the grave with the intent of arriving safely in a well preserved body, but to skid in broadside, thoroughly used up, worn out, and loudly proclaiming Wow! What a Ride!

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#201256 - 06/28/18 02:37 PM Re: New Pack Finished [Re: Bill Kennedy]
OregonMouse Offline
member

Registered: 02/03/06
Posts: 6561
Loc: Gateway to Columbia Gorge
Sorry, I should have taken a closer look! As I mentioned, though, pack features depend on individual circumstances--what works for me may not work for you--and vice versa. It's YMMV and HYOH, again!

Please keep us informed about how the pack is working out for you! It looks to me as though you're onto a good thing!--perhaps the start of another cottage industry in our area?
_________________________
May your trails be crooked, winding, lonesome, dangerous, leading to the most amazing view--E. Abbey

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#201257 - 06/28/18 03:17 PM Re: New Pack Finished [Re: PaHiker]
Bill Kennedy Offline
member

Registered: 02/27/18
Posts: 105
Loc: Portland, Oregon
Thanks for the kind words. Actually, I've made half a dozen over the years, but not for quite a while. Mostly I've used the same basic design, but with somewhat heavier materials. There's a link in the MYOG post with the title, "need suggestions for pack" if you want to see one.

For the zippers (both for lid pocket and on front panel) I used #5 YKK continuous zipper. I just sewed across the ends rather than using zipper stops.

I made the big pocket on the front by starting with the main front panel extra long (maybe 18" or so). I folded it toward the inside of the pack, then back up, making a pocket about 8" deep. Then made another fold above the pocket opening, this time outward-and-back to form the zipper flap, then the material continues on up to the drawstring. So it's all one piece, with one side of the zipper sewn to the first fold, and the other side sewn behind the zipper flap, making sure not to sew it too close, or the flap will constrict the zipper.

Then when the front panel is sewn to the sides, the zipper ends are sewn over at the same time (making sure to put the zipper pull on first.)

I hope that gives you the general idea. As far as zipper installation itself, I imagine there are a ton of YouTube videos on the subject. There's useful tips on thru-hiker.com and also therainshed.com. #5 is about the right size for pack pockets, sleeping bags, and the like. #3 is very light, and works for ultralight clothing and netting zippers on ultralight tents. #8 is for heavy duty stuff, like duffelbags, and #10 is heavier yet. Be aware that there have also been #4.5 and #7 and maybe others. It's a good idea to get the pulls from the same source at the same time as you get the zipper. Also, there are locking and non-locking pulls. The locking ones require a "downward" pull to unzip. Best to avoid for backpacks.
_________________________
Always remember that you are absolutely unique, just like everybody else. -Margaret Mead

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#201260 - 06/28/18 03:51 PM Re: New Pack Finished [Re: Bill Kennedy]
PaHiker Offline
member

Registered: 02/12/15
Posts: 129
Loc: Western Pa, USA
Thanks, I'll check them out. thanks
_________________________
Life should not be a journey to the grave with the intent of arriving safely in a well preserved body, but to skid in broadside, thoroughly used up, worn out, and loudly proclaiming Wow! What a Ride!

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