Help Finding Lighter Aluminum Stays for Pack

Onlinemetals.com

You can order aluminum sheet/plate in custom widths for a given thickness. 1/8" by 1/2" 7075-T6 would probably get the job done.

Before I order… can I bend 7075-T6 aluminum without any special tools (I'm thinking knee/shins)?

In 1/8" thickness, yes.

> can I bend 7075-T6 aluminum without any special tools
Yes for T6, but distribute the bend! Curve it over something large.

Now T9, as Easton uses – that's harder, but still possible.

Cheers

Thanks Dave — I ordered 2 stay-sized pieces of "bare" 7075-T6.

And Roger, thank you for the hint about gently *curving* it. Knowing nothing about a subject means that I need the "guide for dummies". No such thing as "too obvious" here (sad to say).

A rounded railing or particularly rigid chair arm works.

I see you already ordered 1/2" wide stock for stays. There is another way to get skinnier stock, which I have used – I cut them lengthwise. Mostly have done this to get stays skinnier than I could buy, 1/2" being then arrest I hve found. ,I cut 3 out of a 1" stay so I have 5/16" wide stays for my summer packs.

Did you sew loops for the stays to slide into, or is there more of a rectangular pocket similar to how Gossamer Gear and Granite Gear use for their stays?

If it's the latter, you could order a stay from Gossamer Gear and try it out. I thought that their price + shipping was too much, so I ended up making a very similar one out of 1/4" (I think) aluminum rod from Lowes. Mine was around 3.5oz and $5 I believe. The flat style stays you're making may be the better option, but the rod style ones are another option if needed.