REI Flash 45 Frame

Why not bend the stays until they no longer rub your shoulder blades? I have this pack as well and it looks like an easy modification to me.

I have the medium size. I should be in a small. I have them bending inwards toward my back and rubbing against my lower ribs. I find the frame quite pointless in transferring a load based on how much the rods flex. but that also could be because the pack is too large for my frame. I've done longer trips in the 4 day range with heavy water carry in SoCal and what I've noticed more than the frame pain against my ribs is hip pain from the padding(or lack of) on the hip belt pockets and the the ridged nylon trim on the shoulder straps digging into my skin. I am going with an Arc Haul from Zpacks.

I don't think they would bend and stay in place since they are made of delrin, plus the mesh channel they run through allows no adjustment without removing it altogether. I only paid $71 for it so it's tempting to modify it, but of course this voids the warranty so I can't return it. Zpacks do seem like a great option. I just ordered dry bags from them and they were great people to deal with. I live in FL so perhaps they'd let me stop by to try on some products.

You may want to try how the pack carries with the frame removed. The inverted 'U' frame is held in snugly at the top by a flap of nylon. Sarting at either corner firmly peel back the flap so that the top horizontal aluminum bar is free, then just lift out the frame. I found that I preferred the way the pack carried without the frame , but my pack weight never exceeded 25 lbs. Even with the frame removed the pack is still semi-rigid due to the foam backpanel. Because the frame fits in tightly, reinserting the frame requires a bit more patience. Hope this helps.