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I've been using a DIY external frame pack for 10 plus years. I've recently posted details of waist belt, frame, shoulder straps and front bag but it occurred to me that I never actually dedicated a post to a specific pack. This post is dedicated to my wife's pack.
My wife switched to this 11 ounce pack a couple of years ago. It replaced her 4 1/2 pound MSR frame pack. So she saved 3.8 lbs in weight at a cost of less than $1 per ounce saved.
Specs
Fabric is 1.9 ounce uncoated nylon
Vertical frame members are two fiberglass tubes about 1/4 inch in diameter
Top bar is 1/2 inch od aluminum
Connector fittings are 3/8" nylon barbed T plumbing fittings
Buckles are all 5/8"
Webbing is all 1/2" nylon
Bag volume is about 4000 cubic inches(about 65 liters) (assumes open basket style)
More than 2000 cubic inches of stuff can be strapped to the top bar
Bag volume + top bar capacity total is 6000+ cubic inches (about 100 liters)Features
Bag position on frame is adjustable
Squat bag shape gives good volume per fabric used
Padded waist belt with 2" quick release buckle
Padded shoulder pads
Bag, waist belt and shoulder pads can all be cleaned in washer and dryer
All parts easy to make using off the shelf parts/fabric plus some sewing
Bag can be made from 1 or two pieces of fabric
Bag is simple stuff sack style (24" wide (48" circumference) and 25" tall when laid flat
Drawstring closure
Has typically been used to carry about 25 lbs but can carry 40 pounds
Pack can be assembled and disassembled in minutes
Disassembled pack is about the size of a tent pole stuff sack
Assembled pack is small enough to use as carry-on luggage in airplane
Disassembled, empty pack easily mailed or carried inside other luggage
Pack frame flexes with user movements
Tubing/barbed T connections act like ball joints
Pack is uncool-looks like a nerd built it-he did
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