Nick:
Sure, I'd be happy to answer any questions. I used to have a web site which described some of my ideas, but I've changed my mind about some of those ideas, so I'm in the process of rewriting that web site. The fact that I am in Europe in really inconsequential to the techniques I use. What is important is that, unlike most American long-distance hikers, I don't have a bounce box or other means of resupply other than what I can find in stores along the way. So I am very concerned about durability, but not if this causes me to have to lug heavy weights.
I am also very concerned about appearance, since I don't like looking and smelling like a bum. A couple I passed in the Pyrenees this summer were later refused entrance to the same hotel I was in because the man's backpack stunk so bad–they gave him some story about being closed for the summer, though of course that wasn't true given that they let me in. And yet the man was a retired doctor and I'm sure he and his wife had huge French pensions, based on their talk of a detached house in the Paris suburbs and traveling all over the world. The problem was that the man's backpack was one of those heavy framed things and so couldn't easily be washed in a sink and so it eventually got stunk up with underarm smell. I, on the other hand, had a fabric only backpack (a Golite Gust with the hipbelt chopped off and the padding in the back removed) which I could easily wash in a sink to keep the smell down. I assume the man was aware of the stink, given that he had his wife along and she didn't stink. He and his wife also had all kinds of bandanas and socks and other crap hanging off their packs–a really wretched looking spectacle. And their clothes weren't much better: running shorts (they were both past the age where anyone wants to see their legs) and big stomping boots and sweaty t-shirts. Imagine going into a nice restaurant looking like that. I was rejected from a hotel in Spain myself when I came in dripping and probably with a slight whiff of mildew after several days of walking in heavy rain. The woman owner said the place was full, but I could sense she was lying. This is what happens when you look and smell like a bum.
The big lesson I have learned over the years is that the human body can do amazing things, if we just learn to use it effectively. We don't need much food if we are out for just a few days and hence have body fat available, and we don't need much clothing while we are moving, and a man's shoulders can easily carry 20% of his body weight without a hip belt, once the muscles develop. If you get cold, just pitch a shelter and crawl under your sleep quilt or bag. I've done this at 11 in the morning at times when it was too cold for the clothing I had available. A lot simpler than lugging around extra clothing for 6 months that I only need maybe 5 times.
The human body is also quite resistant to illness if we give it time to repair itself and feed it properly. That means plenty of rest and plenty of fresh fruits and vegetables. I routinely drink untreated water and seldom wash my hands before eating and yet I never got sick this past trip. I also walked in sandals with a huge open cut on the side of my foot (sandals have their drawbacks, as that huge open cut indicates) that was constantly exposed to cow manure and other dirt and never got infected–the reason is that I gave my body plenty of rest time to fight off possible infections. I estimate I spent 12 hours a day lying under my quilt, in fact. The main cause of sickness is that people stress themselves out. Watch how a working dog like a sheepdog behaves–as soon as the work is over, it lies down and takes a nap. That's why those dogs can walk barefoot in the mountains and get by on so little food and drink dirty water without getting sick.
One thing about Europe that you should know is that it is technically illegal for me to be there more than 90 days within any period of 180 days unless you have a special visa. I've been breaking this rule for years, but I have a feeling the computer systems are getting ready to catch me, so I'll probably have to start spending large amounts of time in Turkey or the Arab countries in the future, since I don't want to fly back to the United States after just 90 days. This 90 in 180 rule also applies to Australians.
As for getting material shipped to Australia, owfinc.com will do this, I believe, and they have everything you need. The supplex that I bought from rainshed is slightly lighter in weight than the owfinc version, but not enough to make much of a difference. It really isn't necessary to make your own gear to keep weight down. This site is full of information about gear and clothes you can buy that is lightweight.