Which fabric for Mchale Pack

Dan, whom I admire and respect a great deal, will lean you towards bigger and beefier. While I have been abusing my pack for only the last 2 years about once a month for longer hikes and weekly for day hikes, there have been no durability issues. And I expect none either given what is clearly legendary stitching and overall build. Just go as small as you can for 2 to 5 nighter’s and have removable add-ons (kangaroo pocket, expedition pocket, extra large bottle holders, lid, etc.) for longer expeditions. I managed to get him down to 1.9 lbs in small mode. In terms of fabric I used Dyneema because of familiarity but you say that he does not use that fabric now. So my suggestion: go with the lightest fabric possible because the pack will hold up to just about anything you throw at it (or in it).

This is exactly what I was planning on doing. Small pack with removable add-ons. I’m personally leaning towards UltraX 200. Just was wondering if anyone else that would read this would have any opinions.

I have 3 McHale packs. Two with Spectra X Grid and one with full Dyneema. The last is my favorite. The Spector X Grid has held up very well. Dan been using it for a long time. When I got my last one, a LBP 34, I went with the X Grid. At the time he was offering full Spectra, but I felt the X Grid would meet my needs.

The other option I am familiar with is Cordura. In another galaxy, long, long ago I had a Mountain Smith Frost Fire made of Cordura. Burly, but strong material. It is heavier than Spectra X Grid. I would go with the X Grid.

You might want to send Peter Vacco a private message, if he doesn’t respond to this thread. I think his McHale is either X Grid or Cordura. He has thousands and thousand of rough miles on it and it is probably 20+ years old.

I use (non McHale) packs with 200D fabric.  It never rips or anything, plenty strong.

So, ultrax200 would probably be good

I’ve used laminate fabric and it delaminates after a while – isn’t VX21 a laminate?  I think that’s what I’ve used

Can you repair delimitation yourself? Or can you do something in the areas where delimitation usually occurs to prevent it ( like some tape )?

not really.  It starts peeling multiple places.  Maybe you could put polyurethane on it or something.  Me, I just don’t use laminates.  I have heard other people with same opinion, also some people are happy with laminate.  Maybe laminate wears out after a while, but until then people are happy.  If you don’t use it a lot it will never delaminate.

I’ve built a number of MYOG packs and have used many of those fabrics or at least ones similar to them. If waterproofness isn’t important, I would stay away from the laminates. Delaminations often start at stitch holes, and these can be tough to repair with tape since the seam binding that is typically used to finish the seam is in the way.

The Ultra fabrics have impressive abrasion resistance, but even with the newer variants, I think seam strength is less unless seams are taped and/or top-stitched. Dans designs seem complex enough that I doubt he can do that. If you want to use one of the ultra fabrics, I would go with the Ultra200 TX with the inner fabric layer.

If water resistance isn’t a high priority, I think it’s tough to beat the UHMWPE grid fabrics for weight, durability, and stitch holding strength.