What’s led you to retire a backpack?
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With the heavier fabrics, never realized that packs could fail so often.  My reason for putting a pack project aside is that a better one has been built. Here’s a photo of some of the ones that were put aside:
All of them were put away to be replaced by lighter versions, or to make improvements. For example, one post mentioned issues with water bottle pockets. The solution was to tailor the pockets to be just snug enough to hold the bottles securely (one on each side) from falling out, yet easy to pull out when needed. (Quart size Nalgene’s, and you can run upper side buckles through the top loop on the Nalgene to add protection.)
More recently, the heavy 5/8″ aluminum tube shown on the left side of the photo was replaced with .340 diameter from Easton shown on the right. Unlike some other tubes, the .340 does not lose its shape in 2-3 foot lengths. The thick wall of the tube will not fail in normal use (like not being thrown over the side of a mountain). Easton’s temper is very high, yet the tube does not crack in normal use. Yet, as Roger Caffin showed me, the tubing can be permanently bent with a device he calls a “rolling jenny” that works where ordinary tube benders fail. He was kind enough to bend a few of the .340 tubes to be used in sidearms for a light pack that would not fail. And lesser and longer bends, could be made without the jenny. And the sidearms are protected with a sturdy fabric (pack shown on second right). The goal is to make an hourglass shaped internal sidearm frame that will support a mesh backband that will mold itself to the back.  Unfortunately, with some advances in tent materials, free time has been usurped, and the much lighter pack has had to wait. Still, a full pack was made, but is now going to be even lighter with a smaller size. Well under 2 lbs for sure.
As noted above, I was shocked by the failure of pack materials reported here. We must not overdo lightness in order to save weight, by using fabrics that will not hold up. An Australian tent purchased several years ago was made of silnylon with a PU coat. After a few years, the fabric lost its ability to stay taut even when dry, and took on a darker hue. There have been no failures, but intend to use a silcoated polyester for the final build, and have found some polyesters from Yama and some other companies that are very strong and are under l.l oz/sq/yd.
The lesson has applied to packs as well, and nothing will be used that will not hold up. Tested many tarps for the tent project, and was amazed at the poor quality that is out there. So am not surprised by pack fabrics also failing and wearing out too soon.
I’ve also had great luck with the fit of side arm packs such as those shown above. Much better than any pack with a hip belt locked against the tummy. You haven’t lived until you can reach down to both sides of the arms and adjust the tightness on the fly. (So to speak, no joke intended). Hope time will allow for both the tent and the pack to be completed and posted on the MYOG forum. Wishing you all success with gear finding.
My Kelty Super Tioga – I made the mistake (after moving to AZ) of keeping my gear in the garage. After a couple seasons the sticking had dry rotted and I was dealing with zippers pulling out, harness blowouts and on trail repairs.
The older Kelty packs didn’t use polyurethane on the nylon, just plain nylon. The zippers were robust. I have five Kelty backpacks that have been stored in my garage for decades without any problems.
Bought my first Kelty (D4 model) in 1971. It was my go to pack until about 2005. In both 1971 and again in 1972 I did a 6 month trip in the Sierra Nevada with this pack.
In 2012, the interior material separating the bottom compartment from the top compartment ripped out at the seams. I sent to to Kelty to be repaired since I can’t sew. Expecting to pay for it, they repaired it for free under warranty — 41 years after I purchased it. I also replaced the shoulder straps at this time.
About 5 years ago I replaced the hip belt.
I still use this pack a few times each year, though nowadays my go to packs are made by Dan McHale.
Sometime during the mid seventies I found out that Kelty had been sold to another company, and worried that they would discontinue the line of packs, I purchased an early Kelty Model B with the optional two external pockets, mounted on a Mountaineer frame, from the original owner. This pack was brand new, never used. Since my fears about the D4 wearing out or would break never happened, this 50 year old pack has never been used.
Above: trip in 2012
Above: trip in 2020
Here’s an article about my several Kelty packs and a history of the company.
This one, Update Your Old Kelty External Frame Backpack, is about the shoulder straps and hip belts that can be purchased today and an explanation of how to install them.
I remember one version having the upper section divided into the 3 sections. Is that your pack? Looks like a newer hipbelt though; the originals were just a belt and I remember the leather backed foam pads they sold as options. (all available in the early ’70’s at the original store in Glendale, CA).
Steve,
The images I posted earlier are the Model D4 I bought new in 1971. It has four side pockets and a horizontal zipper at the bottom for the small compartment below the main bag, which as I mentioned, Kelty repaired for free about 10 years ago. It has a single compartment main bag.
The version with the three dividers in the main bag was the Model A.
In 1977 I bought a used Kelty A model for my first wife. The original owner had used it once, on a 3 day trip. My wife used it only once, on a 7 day trip and decided backpacking was not for her. I used it a few times also, but not in over 40 years. It is in the garage. It isn’t very practical unless one works to take gear that fits into the compartments, keeping in mind that the sleeping bag/pad is usually carried on the outside under the main bag.
The Model A has the horizontal zipper in the front for a section under the main bag, without the three dividers. It only has two side pockets. But as I said, I bought it for my first wife and bought it really cheap.
The logo (below) on this Model A shows “Glendale 1, CA” and no ZipCode, so it was probably made before 1963 when ZipCodes came out and before Kelty started putting the ZipCode on the logos, which they did.
Both my D4 and the A have the “Backpacker” frame. Below is the frame on the Model A:
Sometime during the mid seventies I found out that Kelty had been sold to another company, and worried that they would discontinue their line of packs, I purchased an early Kelty Model B with the optional two external pockets, mounted on a Mountaineer frame, from the original owner. This pack was brand new, never used. Since my fears about the D4 wearing out or would break never happened, this 60+ year old pack has never been used. I really like the design with a full 3/4 bag and no bottom zippered compartment. I was kinda looking forward to the D4 wearing out and switching to this one, but the D4 refuses to die — that plays into the OP’s question of when to retire a backpack.
Below is the B4 (4 for the number of side pockets) and the Mountaineer Frame, which has an extra crossbar at the top versus the Backpacker Frame.
I did upgrade the shoulder straps and hipbelt a few years ago, just in case Kelty discontinued those too ;-)
No small divider at the bottom of the bag and has four side pockets. This is a really nice pack!
The logo also shows “Glendale 1, CA” so probably made before 1963.
Last summer I was going to take it on a trip. Loaded it up and walked around the neighborhood and it is still in pristine condition. I ended up taking one of my McHale packs instead, just didn’t have the heart to break in the B4 since the newer D4 is still in great shape after all these years.
Below is the logo from my D4. Shows Sun Valley, CA and ZipCode. IIRC, Kelty moved to Sun Valley in 1968 and this was his new logo.
He sold the company in 1973 and the new owners changed the logo. Around 1975 or so I bought a large Kelty Serac and it has the logo that changed in 1973.
Nowadays it seems no one (except maybe Dan McHale) makes gear that lasts a lifetime — I have a full woven Dyneema that will live longer than me and I use more than any other pack these days. It’s a shame we’ve become a throwaway society — even backpackers, many who profess to minimize their impact on the wilderness.
Not that I’m trying to save the planet — I’m a cheap SOB — but I will spend good money on quality gear if it lasts.
I still use my old Svea 123 stoves that are 50+ years old, an old GlobeTrotter stove from the 80s I upgraded a few years ago and an 80s Chouinard Pyramid.
Some examples:
Gaz Globetrotter Backpacking Stove: 35 Year Review
MSR WhisperLite Stove: 35 Year Review
Resurrection: My Chouinard Pyramid Rises From the Dead
Have I mentioned this before? (yes). I wish someone would at least try designing an external frame pack that takes carrying a bear canister into account, using modern materials. My guess is that one could easily rival most LW internal frame packs in terms of weight, and excel in terms of comfort and load shifting from shoulders/spine onto the hips. And create better air space on one’s back and be more forgiving in terms of how its packed.
You might find these pictures interesting. My Kelty D4 has a 3/4 height bag. Weight of the pack is 3.5lb.
Below is the interior of the bag. Note the small metal hold-open bar.
Next is the pack with a BV450 inside.
Will a BV500 fit? Sure but not all the way below top. If the hold-open frame is removed it will fit even lower.
What if we tried to carry and BV450 AND a BV500 at the same time?
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