35+ LB capacity pack recommendation

If you look at your pack weight, how many miles do you expect to actually be carrying 35-40 lbs? Food weight goes down each day and water weight can go down quickly in a few hours (each liter of water weighs roughly 2.2 lbs). In this perspective, some of your lighter options might be best (HMG 4400 packs, SMD Fusion series) as you could only be carrying 35-40 lbs for a few miles on day 1, and then less after that.

Good point, John. But will two bear cans fit into some of these other packs?

John,

Exactly. And exactly why I'm cool with the lightest pack that can do that job. This is my "over 25lb" pack, not my "Imma fill it to 40lb minimum!" pack. I just have done a 30lb day in a 1lb frameless pack, and don't plan on doing that again.

Those weights are all just high-end estimates (mostly to justify the numbers and avoid "why the hell are you carrying 40lbs" questions).

Dave, I don't see where the two bear can requirement is. I just see that he wants to carry a single 2-lb bear can? Seems like the most of the packs suggested should be able to handle that.

John – you are correct. I read that wrong.

Those who have experience with the HMG Windrider 4400, does it ACTUALLY carry well with 40+ LBS?

It is both the lightest and most volume of those suggested.

(apples-apples its 1400 CuIn bigger than the SMD Flight 60)

It has the same suspension as the Porter, and my Porter 3400 has carried 40+ pounds better than even some of the old, heavy packs I used to have. The 4400 has an even beefier suspension.

***EDIT: Also, Luke Schmidt I believe has a Porter 4400, and he can speak more at length about the beefier suspension.

I found the comfort limit of my 4400 SW to be around 35 lbs. It is the older model, so it does not have the plastic framesheet or extended length hipbelt of the current 4400s. The limiting factor for me was the padding on the shoulder strap and hipbelt – loads in the upper 30 lbs resulted in light bruising and sore shoulders. Nothing severe, but I felt like load lifters would have helped a lot.

If I have to carry 35+ lbs again, I'll probably end up using a Deuter pack or just strap things to my SMD Flight 40. I only have about 60 miles on the Flight 40 with loads between 10 and 25 lbs, but it is proving to be the most comfortable pack I've ever used. I can't see myself going back to the 4400 SW.

Check out the Elemental Horizons Aquilo. Got a Highly Recommended rating on BPL in a detailed review by Will Reitveld and many speak highly of the EH packs. There are some BPL members using their smaller Kalais Pack. The Aquilo is just larger volume like you are looking for. It's on my list, and I'd like to get it in full dyneema, though most say the regular body material is fine.