About 4 years ago I bought a Golite Trek. I loaded it up and found that no matter how tight the compression straps, the pack collapsed when I tightened the load lifters. the pack needed some sort of frame. But it had to be light weight.
So I purchased a yard of carbon fiber cloth and some WEST epoxy. Then I built a mold some scrap plywood and waxed cardboard using the aluminum stays from my favorite Mountainsmith Mountainlight to get the curves right. I laid up a beautiful frame that was light and stiff. Then I used the polyurethane foam pad "frame" from the Trek and cut the frame board to shape. After much searching I found a glue that would allow me to glue the carbon fiber to the polyurethane. The only way I could buy the cement was by the 12 can case. The glue worked great. I gave several of the extra cans away as gifts.
Then, with the help of my friend "Draggin' Lady", and her sewing machine we modified the pack to take the carbon fiber frame board. I noticed that the carbon fiber frame board was causing some abraison of the pack material, near the waist belt attachment so I purchased a half yard of heavily coated nylon ballistic cloth and further modified the pack with a reinforced pocket to recieve the lower end of the frame board.
In order to try to reduce the weight of the pack to offset my modifications I cut off the mesh pocket on the under side of the pack's top pocket. I also shortened all the straps to the minimum required and removed the daisy chain and ice axe loops and straps. I then added a small "patch" where I'd removed the mesh pocket, in order to run my belt through and use the top pocket for a day pack. I also added a side pocket to take a water bottle, since the hydration sleeve now held the frame board.
I loaded the pack with about 30lbs. and did a 15 mile day-hike. It worked great.
COST:
Golite Trek $90.00
Carbon fiber $51.72
WEST epoxy system $45.69
Case of spray cement $89.75
Coated ballistic cloth $10.00
Miscellaneous (est.) $10.00
TOTAL $297.16
My next purchase was a Luxurylite pack. I've never carried any other pack since.
Say, did I ever tell you about how I modified a Sierra Designs Half-Moon to make it a four season tent? You guessed it. I never backpack in the winter.
I gotta go home and take off my stupid suit.