Working towards not quite ultralight gear
In 2018 I did my first multi-week through walk and my first serious work on trying to get my pack weight down. I also created my first home made backpack. I'd made a variety of sacks and covers over the years, often from scrap materials and not really light weight. In 2018 I started to play with DCF and related materials.
My pack was based on the ZPacks ArcHaul dimensions and used what I think is the same material for the body. I used a heavier netting for the outside and heavier carbon fibre components for the frame. I ended up around 1.3KG in total, respectable for a first go but somewhat heavier than the ZPack's pack. I also made a pack liner/travel bag and a variety of stuff sacks, pouches etc.
The pack has performed well with the only serious issue being the carbon fibre frame uprights working their way through the webbing which formed the ends. I've since discovered that ZPacks recommend metal caps for DIYers. That fix would not have been viable with mine so I have sewn some Kevlar onto the webbing. I also stuffed up with the side pockets and put them on backwards which makes accessing water containers etc difficult.
The pack has done around 2000km of through walking with me and has been for the most part comfortable. It's kept the gear inside it dry (although the stuff that matters most is often inside multiple layers of DCF with my travel case doubling as a pack liner and most gear inside stuff sacks).
I made a significantly lighter version in early 2019 however it's not worked as well with a major seam split, fixed but I've not trusted it for anything serious since. I've also made a new body using the same DCF as the original this year and will get onto the harness in the near future. It's going to be pretty similar to the original but with some lessons learned applied to reduce the weight but maintain the strength.
I bought the fabric for my original pack from Tier Gear in Tasmania however that's no longer available through them. Most of my fabrics now come from Ripstopbytheroll with other components sourced from various places.
My pack was based on the ZPacks ArcHaul dimensions and used what I think is the same material for the body. I used a heavier netting for the outside and heavier carbon fibre components for the frame. I ended up around 1.3KG in total, respectable for a first go but somewhat heavier than the ZPack's pack. I also made a pack liner/travel bag and a variety of stuff sacks, pouches etc.
The pack has performed well with the only serious issue being the carbon fibre frame uprights working their way through the webbing which formed the ends. I've since discovered that ZPacks recommend metal caps for DIYers. That fix would not have been viable with mine so I have sewn some Kevlar onto the webbing. I also stuffed up with the side pockets and put them on backwards which makes accessing water containers etc difficult.
The pack has done around 2000km of through walking with me and has been for the most part comfortable. It's kept the gear inside it dry (although the stuff that matters most is often inside multiple layers of DCF with my travel case doubling as a pack liner and most gear inside stuff sacks).
I made a significantly lighter version in early 2019 however it's not worked as well with a major seam split, fixed but I've not trusted it for anything serious since. I've also made a new body using the same DCF as the original this year and will get onto the harness in the near future. It's going to be pretty similar to the original but with some lessons learned applied to reduce the weight but maintain the strength.
I bought the fabric for my original pack from Tier Gear in Tasmania however that's no longer available through them. Most of my fabrics now come from Ripstopbytheroll with other components sourced from various places.
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| The travel case/pack liner is a little worse for wear now after being subjected to processing 17 times in airports as well as about 2000km of back packing |
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