About a month or so ago, I decided I wanted to make my own pack or packs. I already own several high end very well designed and manufactured packs but there is something about making something for yourself, designing it, making it, tinkering…..
I decided that for the first pack, I wanted to use a cheap material but something with similar handling properties to the fabrics I aimed to use for the final version. My desired fabrics for the final pack are Dyneema Grid Stop or Cuben (DCF). They both have similar stiffnesses to tyvek so I picked up a small roll of 63gsm tyvek.
Although I had used a cheap main fabric, tyvek, cheap mesh, webbing and hardware, I created the pack using the same processes that I would with a more expensive fabric.
I managed to buy a small roll of tyvek on eBay for a relatively good price and from it I made this pack, cut out some new ground sheets and a bathtub floor for one of my shelters. Taking into account the amount of tyvek used for the bag and including all the other bits, I would estimate that this pack cost me around £25 to make.
Tyvek…I must admit I did wonder how it would hold up but in all honesty, its pretty strong stuff and as long as you reinforce carefully and where needed it will last. I weight tested this pack, initially with 5KG and then 7KG and it held up fine, not loose stitches or other wear.
Leap forward a week and I was already planning my next version. This time I wanted to make a pack using a more workable fabric. I found the tyvek great but it was a pain trying to sew in some instances. I already own a pack made from XPAC and decided that this was what I would use.
I did a little research and just before I was about to order the fabric, a post was put up on the Trek Lite forum about an American stockist now with a EU store where the prices included all customs. I checked them out and placed an order.
While the fabric was on its way, I sat down and tinkered with my design. I ideally wanted to create a 30-35litre pack internal storage with two side pockets and a large mesh pocket. Drawings made, measurements worked out I waited for the material to arrive.
Materials used;
-  VX21 – Back panel, shoulder straps, side pockets and hip belt.
- VX07 – Side and front panel of pack including the mesh pocket cinch channel and lower attachment
- 4mm 3D Spacer Mesh – used on shoulder straps and hip belt
- 110gsm fishnet – front pocket
- 10&20mm Grosgrain – Various
- 20&25mm webbing – Strap attachments
- Plastic Hardware – Various
As I have materials left, I have take the price per meter of each fabric/item and worked out how much I used. This second pack came in at around £47 to make. This would be more if you were buying by the meter for a single pack, somewhere in the region of £69.


Finished pack








