Interesting observation. I'm having the same issue with the UL packs I've tried out so far at home (GG Gorilla, etc.). The main problem for me is that the bottom of the pack ends up resting on my spine just below the small of my back. Not comfortable. I just posted a description of this, with pics of my wearing my Z55, on my "Sub-2 lbs pack" thread just a few lines up (well, I suppose now it's down?).
Nick,
Your post on the McHale line of packs is rather serendipitous. I was just browsing McHale's website today, thinking about whether a custom pack would solve my fit and low back comfort issues.
Do you know if McHale makes truly UL packs? I mean, could he make me something that is just as well designed with a suppportive frame with a total weight of around 2.0 lbs?

