Sew bottom panel edge with bottom
edge of front panel (1/2" seam). Then sew another stitch line parallel
to it but 1/4" from the edge (for reinforcement I recommend that you use
seam tape to prevent fraying. You can actually make your own seam tape
from a length of 1 1/4" 1.0 oz. coated nylon or any similar fabric.
Sew the rear edges of the top cover/lid
to the top edge (about 2 1/2" at the top sides) of the back panel wrong
side out. Refer to photo 20.
Sew side panel(s) assembly to the
connected piece in item 33 inside out with 1/2" seam (this is a main seam
and we have to be a bit lavish for the allowance). Apply seam tape and
sew at least two more parallel stitch lines all around these main seams
Turn everything inside out and you're
ready to connect the collar to the top edges. Cut the collar components
according to figure 19. If the fabric you're using has a noticeably coated
(i.e. a bit sticky) underside, we're going to sew the sleeve in such a
way that the uncoated side is adjacent to the cord. Otherwise, you'll have
a little difficulty in cinching the draw cord smooth and tight because
the coated side of a fabric tends to get caught with the cord.
Fold the ends of the collar 3/8"
inwards (towards the coated side) and sew. Then fold a long end (along
the length) in a similar fashion and sew.
Sew collar short ends together inside
out along (3/4" from the edge outline) the short ends but leave a 2 1/4"
long unsewn end (at the folded edge for the drawstring sleeve). Next, fold
inwards the unsewn end flat as shown in figure 20.
Now, we are ready to sew the sleeve
for the drawstring. Fold the "finished" long end of the collar outwards
(or towards the uncoated side) up to the 2 5/8" (from the edge outline)
shown in figure 20.
Thread cord through sleeve and fasten
cord lock to the ends and secure with a stop knot.
Sew collar to top edge of pack bag
assembly in such a way that the cord lock seam line (it is where the collar
short ends are sewn together) is aligned with the center of the back panel.
Sew the connection seam again flat inside so your stuff won't get caught
in an otherwise exposed seam.
Thread all webbing (shoulder strap
webbing, hip belt webbing, top cover/lid webbing) through their respective
buckles. Thread the lace/cord for the compression as you would lace up
a shoe and then secure ends with a cord lock and a stop knot. Fold (about
3/4") and sew all strap ends so that they won't accidentally unthread by
themselves. You may add a sternum strap assembly to complete your project.