Running Vest Frame Sheet?

The bladder isn’t breathable, so placing a non-breathable layer of material next to it shouldn’t make much difference.

Duro 6 owner here… What are you using the front pockets for?  I’m a recent convert to soft flasks in the front. The 500ml ultra flasks from Hydrapak with the hose extension fits perfectly in the pockets. I realize this doesn’t scratch your tinkerer itch, but it’s a pretty comfortable set up.

If you’re set on the bladder, another option would be to sew a ladder of foam along the backside. You could play with the spacing to get you airflow you want.

@Rene….that is a very good point

@Eddie: I’m using front pockets for water as well, when needed. I’ve tried flasks only, bladder only, and I prefer flasks in front, but the route I have planned is going to require both flasks and bladder (or another solution to get to ~2.5L)

Maybe you can start experimenting by zip-tying a small piece of foam pad to the slider.  Once you’ve got the geometry figured out, then you can think about how to get a more permanent integration with the vest – or decide modding the slider is all it takes.

You might also consider modifying the slider itself.  Grind off the part that pokes you.  Add something like Sugru or epoxy to flatten out the flared end, or maybe even 3D print a new one that won’t poke you.