Let me start by saying that I do not know how to sew. But there is a question that has been nagging for a few years. Whether it’s removable hip belt pockets, shoulder pockets, or pack pockets (side pockets, front pockets/talons)…. We have been working with DCF, Xpack, Ecopak for quite a few years now. We have these close to waterproof fabrics, but these pockets can have a significant amount of water coming in. On my last rainy outing, while using two hipbelt pockets from the same manufacturer, one side had a significant amount of water (over a tablespoon), while the other was just moist… I made sure to close both “tightly”.
So how can we reduce water ingress into these pockets? Three possible construction options come to mind for me:
Rolltop would be the easy answer. Because of the taller collar, this design may work better in a hipbelt where the pockets are situated lower in your body, making it easy to see in. Or perhaps on pockets attached to the main back, such as side and front pockets, since these are typically accessed when putting the pack down (although it would be hard to ask someone to fetch things for you without taking the pack off unless they are significantly taller than the user). I don’t think this design would work well on shoulder pockets because the collar would perhaps reach too high.
I also feel that the current designs could be maintained by simply sewing the zipper a bit higher on the lid, i.e. extending the lid edge past the point where the zipper is sewn. This way, the edge of the lid would go over the full width of the zipper and have water roll over it. I think this design would achieve two things. First, it would eliminate the need for less durable waterproof/resistant zippers. Second, I feel that the design would look nicer and cleaner without that black line of zipper being visible, although I guess the zipper pull will still be there.
Third option, which I think would be my preference on removable side and front pack pockets, would be a sort of 360 lid. Kind of like the picture below. I have seen Zimmerbuilt employ a similar pocket design on a couple of custom packs featured on his site, I think. Although I can’t find them right now. This design may work well for shoulder pouches, but I am not sure about hipbelt ones. One advantage of having this design on the shoulder would be that for the same dimensions, you get a full opening rather than having the zipper limit entry. Another is that folks in environments prone to zipper failure wouldn’t have to worry about it. What I mean by this 360 lid is what is sort of what is pictured on this link
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