All this reminds me of my first Prophet protos (#1-#73) 4+ years ago. It ended up about an ounce more than I had hoped. Then I weighed each and every piece of strap, material and hardware before assembly. What I discovered was than the body (mesh pocket(s), front and rear body panels) weight added up to roughly 50% of the pack. The hardware, padding, 3D mesh, straps, reinforcements, tape, adhesive, etc. was the other half. So, it was clear that to make it lighter using lighter fabric was only a small part of the equation as I was already pretty light there, so, no where to go. (Now there is Cuben and that offers maybe a %10-15% possible savings.) You can see the jist of the analysis here: To trim significant weight ( and maintain size and most features, you would need to trim the other stuff and again that’s pretty tough due to the difficulty and delacacy of making stong connections between the light materials.
-Hope this is some insight for the DIY’ers anyway.
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Hey Ron. Yes… there certainly is an art to balancing the factors of weight, strength, reinforcement, features, etc… not to mention costs.
Your post also gives me a thought. There seems to be a lot of innovation in insanely lightweight fabrics… but not so much in all the other components. As you say… even using Cuben only gives you about a 10% weight loss. Maybe we need carbon fiber buckles… LOL. That would only double the cost of a pack… if such a thing existed :)
Seriously though… I wonder if strap material could be made lighter and stronger? Nylon webbing straps haven’t changed since they were invented. You should get on the phone with DuPont (or whoever)! Tell ’em we need lighter stronger straps so we can shave an ounce off of our 5 oz backpacks. They’ll get right on it I’m sure :)
Wow, it is nice to see that someone finally noticed my little web site =)
Thanks for all the comments! (The good and the bad).
Just to clarify, zpacks.com is a hobby of mine, I love designing and making gear, and I apologize for any unavoidable similarities between my gear and other builders. We are small scale and don’t mean to usurp anyone.
To answer a few questions:
The draw cord has a cord lock which is secured through a loop at the base of the pack. This allows you to shrink the pack as your gear decreases and also add some compression. Someone mentioned the tall-ish height; the drawcord pulls the top down.
The waist belt is just 1.5″ width nylon webbing. It is easy to trim to size. Cutting it off would drop 2.4 ounces. I have a unique and lighter belt coming on the next generation of this pack, available who-knows-when. (2007?)
Yes there is minimal 1.9oz reinforcement, but every stress point (straps, pocket corners, loops) are backed by it. Our packs have held up well in our testing, and as far as we know our customer’s packs have too. We hope you will try it out and please let us know if you encounter any problems or have any ideas!
I agree with Ron that the next big weight savings area is in all the detail stuff necessary to make a pack bag into a backpack. I am on a constant quest for lighter material.
The external pack frame I am currently working on will have the shoulder straps and hip belt made as part of the frame. The setup will use no webbing and most of the fittings will be made by me out of Aluminum. The frame will be very light and will work with several different sized pack bags. I have settled on a weight goal for the complete frame of a pound plus. It will be very light but only testing will tell how well it all will work.
My pack bag will be about the same size as my first Cuben Fiber Pack Bag which was just a little larger than the G6. This pack bag will be sized to support a SUL – AT Thru-Hike and might end up the same size or maybe a little smaller than the current G6.
I ordered a ZPack Z1 last night :)
The ZPack Cuben Fiber stuff sacks I ordered arrived promptly. Upon inspection they seem well made and the toogle and drawcord are appropriately sized. The weights are:
Large .4oz or 12 grams
Medium .2oz or 7 grams
Small .1oz or 3 grams
The large size, that I was shipped, is giant. The medium is likely the most useful size while the small could be useful for small items like gloves and hat. The stuff sacks do not have inner opening flaps nor do I think they are needed as the opening closes to the smallest degree. The large stuff sack I was carrying weighs 1.6 oz. My Campmor mediums weigh 1 oz. By comparison, the BPL SpinLite small is appropriately sized for jackets, has flat felled seams, and weighs .3oz. The Cuben Fiber fabric is see thru (a plus) and waterproof (not seam sealed), tear resistant, but is not recommend for objects other than clothing due to its relative lack of puncture resistance.
Replacing 1 large and 2 medium SilNylon with Cuben Fiber equivalents cost me $45 and saved me 2.8 oz, and added a degree (IMHO) of water resistance.
Recommeded (before field testing).
I just got my Z1 pack. The first thing I did was to cut off the waist belt. I left 1″ of webbing in case I ever want to sew on a smaller, lighter, removable belt. With this modification, the pack weights 108 grams / 3.8 oz. That’s absolutely amazing for a 2600 ci pack made from Silnylon. It has, by far, the best weight to volume ratio of any pack out there.
The extension collar is a very generous 12″… which should allow me to carry extra food when needed… but still compress the pack down quite a bit… as I won’t always need the full 2600 ci.
The rear pocket is huge and stiched with gussets on the sides… near the bottom. The side pockets are also very roomy. More than big enough for 700mL soda bottles or 1L Platypus bottles. The side pockets also have gussets at the bottom. All of the pockets are bar tacked at all four corners.
The craftmanship is superb. Very neat, tight stiching, double stitching on every seam, and very robust bar tacking. The robust bar tacking combined with 1.9 silnylon backing for reinforcement points seems good to me. I’m not worried about those shoulder attachment points now that I see it in person.
The shoulder straps are two inches wide. I really like this width (about the same as the MLD packs). I find this width of strap settles in nicely on the inside of my collar bones. I find the straps on the Gossamer Gear packs to be too wide and creates hot points on my shoulders… on the collar bone points. The straps have a VERY soft cushy padding inside that’s about 1/4″ thick. One thing the straps lack is 3D mesh. They are just silnylon on both sides. I’m not sure if this really matters or not. Time will tell.
The way the pack closes and cinches down is pretty unique. The drawstring (a VERY fine spectra cord with a medium size toggle) exits the extension collar from the back and acts as both drawstring and “compression” strap. The way it works is… you tighten the drawstring and then pull the cord down and hook the toggle to a small loop at the bottom of the pack. This makes the extension collar kind of fold over on itself. Not sure how water tight this would be… but I always use a pack liner anyway. I may try using a double toggle on the cord… one to cinch the drawstring really tight… and the other to hook into the loop at the bottom of the pack.
Most of the pack is made from 1.1 Silnylon. The bottom, straps, side pockets and reinforcement are all made from 1.9 oz silnylon.
So what is the pack missing? Well… it has no lashing loops… just two small loops at the top of the back pocket for hooking things to. That means you can’t add a compression shock cord or strap a pad to the back. Personally… I never use compression cords anyway… and with a 2600 ci pack… there will be plenty of room for my pad inside the pack. One thing tho’… the main bag has just one seam… up the back. This is a plus I would say… fewer seams equals more strength and fewer places for water to get in. However… this design does not lend itself to adding lashing loops… which would normally be added in at a seam.
It also have no “ice axe” loop. Another feature which I have never used on any pack I’ve ever owned.
There is also no sternum strap. Again… something I never ever use. I like to keep my chest cavity open and unrestricted. I know others who always use a sternum strap tho’… even with light loads… so this may be an issue for some.
There is also no daisy chain or other loops on the shoulder straps to lash soda bottles to… like on the MLD packs… but with the side pockets… there is no longer a need to lash bottles to your straps. It’s going to be soooooo nice to go back to having a pack with water bottle pockets… on BOTH sides! That’s one thing I REALLY miss from my GG Mariposa days (my kit has gotten too small for the Mariposa).
Overall… I’ve VERY impressed. Find me another 1.1 Silnylon pack out there with 2600 ci for 3.8 oz. Imagine if it was made from Cuben! Yes… if offers none of the “bells and whistles” of some other packs… and some may question the reinforcement points… but in exhange for those bells and whistles (which I never use… or I use… but only because the pack lacks volume or pockets for my pad and water bottles)… you get more than enough volume and… best of all… 3 pockets! One huge back pocket… and two independent side pockets sized and placed specifically with water bottles in mind. Excellent :)
To top it all off… it’s also the least expensive pack in it’s class.
I’ll post some close up photos next… and I may actually get to try it out this weekend.
Here are some detail photos of the Z1:

Top of shoulder strap – outside

Top of shoulder straps – inside pack

Top of shoulder strap – inside pack

Top corner of side pocket

Shoulder strap buckle / webbing attachement point

Shoulder strap webbing attachment point at the bottom of the strap – ouside

Shoulder strap webbing attachment point at the bottom of the strap – inside the pocket

Top of large back pocket with loop for hooking stuff

Top of extension collar
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