Help Finding Lighter Aluminum Stays for Pack
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May 18, 2015 at 9:32 am #1329015
I'm almost finished a MYOG X-Pac backpack capable of heavy hauling. Finished pack weight is a bit heavy, though, at 3lb 2.5oz, with 2 aluminum shaped stays.
The stays I have are rated for up to 50lbs and weigh 6oz for the pair; that's overkill because I can't carry 50lbs!
I know nothing (NOTHING!) about metal, but surely I could get something lighter that would be good up to 40lbs (my worst-case scenario for water caching)? Any new stay must fit the current stay pockets on the pack.
What (if anything) could I get that would significantly reduce the weight of the stays, while keeping the "hauling" ability? And just as importantly — WHERE would I source these? Edited to add — I would need something "ready to go" because I also have no tools for metal fabrication.
A photo of one of the current stays [22" long (following the curvature) and 1" wide]
May 18, 2015 at 9:50 am #2200440
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.May 18, 2015 at 10:11 am #2200443
Before I order… can I bend 7075-T6 aluminum without any special tools (I'm thinking knee/shins)?May 18, 2015 at 11:02 am #2200459
In 1/8" thickness, yes.May 18, 2015 at 4:12 pm #2200554Roger CaffinBPL Member
@rcaffinLocale: Wollemi & Kosciusko NPs, Europe
> 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.
CheersMay 18, 2015 at 5:02 pm #2200560
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).May 19, 2015 at 9:09 am #2200712
A rounded railing or particularly rigid chair arm works.May 19, 2015 at 7:50 pm #2200876Paul McLaughlinBPL Member
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.May 20, 2015 at 9:17 am #2201000[ Drew ]BPL Member
@43tenLocale: Central Valley CA
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.
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