Golite Ion Modifications

looks good! how much did it add to the weight of the pack?

Awesome stuff!!! What is the added weight and possible extra CI??

Where did you get mesh?

Thanks Jim

I finished up late so I didn't take time to measure the weight. I'd estimate its only an ounce or two putting me in the 10 to 11 oz range.

I got the mesh from OWFINC.com. If I make a rev 2 effort I'd probably look for stretch mesh and add the bungee system over the back pocket. I intended to do that this time around but forgot to do it because the sewing machine and I weren't getting along last night.

did you take the pack apart or just sew it straight on the pack? That's the main thing that was keeping me from buying the ion, but if i could find some mesh… hmmm… now you got me thinking…

I took out the seams down the side and left the rest of the pack intact. That gives you enough access to sew the long runs without getting the fabric twisted. I think it would be tough to do a very good job without ripping out those seams.

that's what i figured, but figured i would ask. I just couldn't envision my sewing machine doing it with out tearing the pack apart. thanks.

Don- That's some darn good sewing and a nice looking Ion. I wonder when Golite will get their act together and realize that most of the serious users of this pack are lusting after just this kind of mesh pocket system.

about the time they realize they need to quit adding weight to their larger packs… I'd like to be down to an Ion by the end of the year and if i were to add this nifty modification i could easily be down for using an Ion. I store my water outside the pack and would like somewhere to stuff a wet tarp or bivy away from my bag or quilt.

I'd doubt Golite will ever get around to adding the mesh. Luckily, you can buy a Gossamer or MLD pack and get the same end product with more options available and better fabric. I got this one on a steal and wanted to try out my sewing skills. I think I was in a little over my head but it worked out.

Final weight: 10-3/8 oz

Looks to me like you did a great job!

I'm trying to modify my Golite Ion by putting two side bottle pockets and a rear pocket that will hold a 2L platy.

On the second picture of this thread's original post, the side pocket follows the curved seam, however that pocket doesn't look big enough to hold a 1 liter bottle. I can make a square billowing pocket, however how do you make a billowing pocket along a curve? I can't seem to make a pattern that will work.

One of the flaws of my first revision was underestimating the amount of material required to allow sufficient volume for storage. I wanted to keep water in the back of that version and there's no way to get anything of significant size in there with the pack full. I'm doing two things to address this in my next version:

1. Use stretch mesh.
2. Add more material to give volume to expand. I made my original pattern by tracing the associated panel on the pack and freehanding about 2 inches of spare material (1 in on either side). This results in almost no storage space – should have been obvious. :( On my new pattern I cut the template down the middle then added the spare material between the two halves by taping in paper of the right width. You can use this as your new pattern to cut the panel of mesh or stretch mesh. Sew both sides, then sew the bottom using darts to take up the slack.

I hope this helps. Let me know if something wasn't clear.

Thanks for the response.

Are you describing the process for the back or side pocket? I'm only confused about the pattern for the side pockets as I can't figure out how to make darts or pleats along the curved seam without negatively effecting the alignment of the seam.

An alternative might be to not use a pattern and just use a lot of material and sew along the curve making pleats as I go until I get to the bottom where the shoulder and hip straps are attached, then sewing the side straight up to the top of the pocket. I could then trim excess material, but this way would probably leave more room for error?

At this rate, I might just end up putting traditional square bottomed side pockets on, although they would have to be higher up on the pack than desired to avoid the curve. Stupid curve.

EDIT–Actually, is it even necessary to make pleats or darts along the curved seam? Can I just make 1 or 2 larger pleats at the corner by the pack strap connection?