Custom Aluminum Hyperlite Stay
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Finally had a chance this holiday weekend to get to a project I’ve been wanting to do for a while now. Create a custom “U-shaped” bent stay for my Hyperlite SW3400. I’ve taken a piece of raw 1/2″W x 1/8″T (same as stock) straight, flat aluminum rod, in the 6′ length, which I hand bent and hammered finish, to create a U-shaped stay that will replace the two stock Hyperlite stays. After bending and forming, cutting off the excess length to match the stock and sanding smooth. I’m satisfied with the end result. Considering I wasn’t using any hydraulic systems to bend the alloy, as well as bending it, in a way, against the physics it normally wanted to bend in. It surprisingly worked itself out quite easily. Even though adding the additional metal into the “U” portion of the frame, the weight has come out the same as the stock stays (4.2oz). The stay fits naturally into the stock sleeves and still utilizes the velcro straps to secure it into place. I’ve bent and formed the frame to the curvature of my back (same as the stock stays). Loaded my pack with around 25 lbs, and it holds more transparent next to my back, forming to my back and transferring the weight more naturally than the stock stays have. I’ve done numerous modifications to this bag and can’t wait to put this into trail use where I can get more real world results out of this mod.
@ Marcus I’d be amused if Hyperlite all of a sudden started offering this
@ Jason Minor adjustments really. Numerous was heavy handed. I’ve done several other things to it. Cut out the main compartment mesh pocket and DCF taped the remaining fabric to make it smooth. Putting gear in and out of the bag always caught on the fabric enough to annoy me. If anything was in the pocket you lost some usable space.
Doubled over and bar-tacked the fabric on the “hand loop” between the shoulder straps. I always use it to hoist my bag on and off. Gives a sturdier grip and differentiates the straps fabric from the “Y” straps that go over the top of the bag. When taking off the bag and blindly grabbing at straps I would sometimes grasp the wrong webbing. This made it obvious by feel which one was which.
Cut down the hip belt webbing to my size and doubled over and bar-tacked the fabric to keep from easily slipping out of the buckles if I pulled it out too far. Did the same to the side compression webbing straps. Except I kept them stock length.
Added elastic cord to the front pocket. Criss-crossed through the stock plastic attachments. I use this to tighten down my load if I’m carrying a lot in the pocket/through brush. As well as attaching CCF pads or whatever fancies.
Put better gripping zipper pulls onto the hip pockets. I’ve also over time added DCF tape here and there inside the bag to re-inforce certain areas. But I consider that more maintenance to wear and tear.
@ Jason Until you mentioned yours, I’m not sure why I’ve left the triglides on mine with the shock cord. I suppose I initially thought they could be of use. But they never have. Will be removing those. It’s kind of amazing that we’ve both gone through the same thought process on this bag.
@ Jerry Yes, my thoughts exactly. I was really concerned that would happen. There are no stress fractures, cracks or wrinkles that would suggest any concern in the end result. Sanded smooth, only kind of roughled (hammered like finish) where I did most of the hammering. It was really quite malleable. I had to make sure while I was bending it, to keep the shape flat (with the hammer) as it wanted to fold over itself. Trail testing this will be the true tell. But until then.
@ Chris I picked it up at my local Lowes home improvement store. Description says it’s 6063-t5. Highly formable, high tensile properties, light but strong. So far it checks those boxes
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