I posted a similar query about a year ago, but we're still looking so here goes again:
My wife is very prone to pain from her collarbone down to her armpit that ends up radiating down her arms after only about 20 minutes of hiking with a backpack. She felt this with an Osprey pack, a Boreas pack, and the ULA Circuit. I think the Gregory we tried at REI didn't fit well either. The only pack that seemed to work was the Kelty PK 50. The Kelty fit great, but the design is futzy and there was an attachment point that was coming apart after about 100 miles on the trail, so we returned it. At this point, we're inclined to buy the Kelty again unless someone has an idea of what might be going on.
The Kelty has a fairly burly aluminum stay that goes down the spine of the pack. I wonder if that is related to why it worked while the other packs didn't.
Our needs are a 50 to 60 liter pack with a weight capacity of around 30 lbs. Lighter is better, but comfort is the top priority.
Any suggestions would be greatly appreciated! We're itching to get back out soon.
Gene

