My DIY/MYOG alpine backpack. Seemingly simple and very thoughtful design.
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I designed this after researching historic and contemporary backpack innovations. There are other bags out there similar (which you may recognize) but not exactly like this in the details, which is why I had the impulse to make it. I designed the pattern using a plastic sheet, Tyvek and carpet tape. Sourced the appropriate materials and my sister (a pro fiber artist and metal smith) put it together with some bomb proof stitching! Instead of buying a new pack and complaining about its weaknesses as I always have, I thought it best to make this one where I could shape and re-invent all the details.
A fair amount of adjustability is built into the shoulder and hips without adding additional weight and the padding is far more substantial than anything I have ever seen on the market. I tried to limit the use of the weak plastic hardware (side release buckles, ladder locks, cord locks, etc.) that all bag manufacturers insist on sewing into their designs. That being said, if one still wants to use that stuff, it can easily be added to this bag as needed and then removed if not needed. I generally carry 18-20 lbs of gear on summer backpacking outing and 22-26 lbs in winter or 30 lbs for remote alpine rock climbs. I wanted one bag to do it all so the 4 oz removable frame has been essential. I used this pack very recently on a number of backpacking trips and a remote alpine climb (where the external gear attachment lashing worked great using a few feet of shock cord). The verdict is in now and it outperformed every pack I have had by a long-shot!
I chose Cordura 1000 for its bomber durability because I shred backpacks made of anything less durable due to my backpacking route choices (I am not a through-hiker. I don’t stay on trails all that much). A backpack manufacturer using the same material would make it weigh twice as much as mine because of all the sewn in hardware and complex seams they like to use!
Bottom line:
Weight is 32oz with full padding and the Gossamer Gear internal frame. Padding in this pack is removable, and up to two layers of 7/8″ EVA can be inserted into the padding sleeves. Using a single layer in the shoulders and lumbar and none in the hip sleeves reduces weight and is very comfortable. I have very boney shoulders and no hips so I can’t tolerate the flimsy padding on all the packs available designed to carry 40 liters or less. If I were to use XPAC fabric, more weight would be shed but I opted for the Cordura because in my personal experiences it has always been the most reliable. I could have made it out of some Dynema-type fabric but it would maybe last two years for me that way and I don’t want to ask my sister to sew me a new pack that often! I still cannot fine a pack on the market this durable that weighs less and has good padding.
The only hardware this pack requires are two metal 1″ slide adjusters, two Z-Packs ladder lock slide adjusters, and the GG frame. The accessory cords on the pack are adjusted using 3mm paracord prusik knots. Something I thought of but have never seen before on a pack!  Alternatively, one could use 550 paracord with 2mm cord prusiks to save a few ounces or shock cord. The cord is only needed if I am attaching a jacket, tent, helmet, or crampons to the outside of the pack.
I will upload more pictures of the pack if there is genuine interest here in the MYOG forum.
Lastly, thoughtful criticism and further innovation ideas are welcome so please chime in with any thoughts.
Waist belt and lumbar pad are removable for lighter loads. Waist belt has a large vertical adjustment, which can be adjusted very quickly with this velcro arrangement.
2 layers of 7/16″ EVA makes a huge difference! Sleeves that open make it easy to remove padding when smaller loads are carried. Shoulder pads are attached using a thin metal slide adjuster. Shoulder pads can be adjusted vertically up to 3 and a half inches!
Adjustment with Prisik knots rather than plastic side release adjusters.
Pack compressed, frame and most padding removed for day trip/climb
           Waist belt in normal position. GG internal frame modified just slightly for my back shape. Despite the appearance here; due to the thick lumbar pad, the frame actually doesn’t make contact with my back allowing my back to breath.Waist belt in climbing mode (moved substantially up to accommodate climb harness)
Lift-loader cord uses prusik knot on shoulder pad rather than the typical plastic ladder lock behind the shoulder.
Thanks for the feedback fellas.
Bear can fits vertical with ease. Actually, that was one of items that determined the measurements of my pattern! It’s a mandatory burden in most of the places where I backpack. Diameter is approx 33″ near the top of the pack.
Maybe these pictures of the shoulder pad attachment point will help clarify. There is a metal slide adjuster sewn in and the shoulder strap has a length of webbing that slides through the metal slider twice to secure it. I had considered just sewing the shoulder pads directly to the back panel and this is still an easy thing to do in the future. I was apprehensive about stitching them down, which won’t allow vertical adjustment.
It’s a fair point about the webbing possibly detaching over the long run. Now that I know where I like them I could just sew the shoulder pads down permanently in the more typical way…. However, I noticed Z-Packs doing a similar thing on the Arc Blast and they use much less robust fabric. Most of the tension on my packs shoulder straps are pulled from the lower box-x stitch while wearing the pack. I should definetely add some additional zigzag stitches above the box-x stitch.
Frankly, I was more worried about the webbing sliding though the metal slider but even with 30 pounds it stayed put while backpacking.
I think I could have shaved 3 ounces at best if I used X-Pac fabric instead of Cordura 1000. Still a worthy consideration for a future prototype, you think?
Z Packs Arc Blast shoulder pad attachment picture here. Are these vertically adjustable? Looks like it is but I’ve never had the pleasure of using one of these… Anyone here know?? The Arc Blast seems to be a really fantastic pack and I considered buying this instead of making one but I’m pretty sure I’d shred the bottom of this pack in a year and my shoulders would hurt if I carried anymore that 18 lbs with those thin pads… Â Perhaps they’d consider adding an additional abrasion resistant layer on the bottom and thicker padding. I know people who carry extra stays when they hike because those vertical tubular stays break on these packs!
You’re correct…Zpacks calls it “adjustable torso height” and Joe demonstrates it around the 2:00 mark in this video:
By the way, it looks like you’ve got a great pack there!
           Waist belt in normal position. GG internal frame modified just slightly for my back shape. Despite the appearance here; due to the thick lumbar pad, the frame actually doesn’t make contact with my back allowing my back to breath.
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