MYOG Pack Durability

If you want to avoid failure in the field, you better load it up with about 20% more weight than what you expect to carry, and test it that way.

–B.G.–

My pack is silnylon but the shoulder straps are sewn to 200d Oxford.

I reinforced the shoulder attachment with grosgrain. I did bar tack through grosgrain and 200d. Then sewed around the perimeter of the grosgrain to transfer the load totally to the 200d. I've used the current version pack for about a year without problem.

You're probably okay without the grosgrain. Inspect it good after each trip.

I go through the same worries as you every time I make a pack. How does one determine how light they can go if one doesn't build one light enough to break?

I wear my pack every day going to the gym and hauling groceries home. Bugs and flaws can then be corrected before hitting the trail.

When I do hit the trail I carry spare parts, webbings, etc. to repair things if they fail. It is also fun to experiment with things on the trail and extra buckles and webbings make that a lot easier.

Put the empty pack on the floor, stand on it, and try to rip the shoulder straps off.

^
That's exaclty how I tested my construction on my new 2oz MYOG pack.

Carry a little repair kit with a little bit of webbing, fabric, needle, thread and small scissors. The most common cause of pack failure is airline baggage handling.