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Boundary Waters Quetico Forum Group Forum: Do It Yourself Gear V2 Ultralight Portage Pack |
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02/27/2022 09:25AM
As I mentioned in the follow-up to my first portage pack build, I did almost everything pretty well (other than sewing), but there are some areas that warrant improvement, so I'm using the solid water season to build Version Two.
As before I am hoping to build a pack that is:
*Very light - empty pack weight around 20 ounces.
*Short height - anything above the shoulders may interfere with my 4.5 oz solo yoke (Build thread here )
*Waterproof
*About 44L for the pack body…plus some pockets. (slightly smaller than V1)
*Padded hip belt
*Comfortable enough at 25 - 30lbs
*Accessible pockets - both for portaging but also while in the canoe
* New: Map Pocket, just a simple sleeve to quickly stow my map during the portage.
V1 dimensions of the main pack body were: 24" high x 14" wide x 9" deep.
V2 size will be 24" x 14" x 8".
Unchanged from before (text copied almost verbatim from my post on V1:)
That last item (the accessible pockets) is tricky. Traditional pack pockets are:
1) on the sides (and if they zip it is on the pocket’s top)
2) on the top/lid
3) on the ‘front’ (the side away from your back)
When I drop my pack in the canoe I put it behind me (dog goes in front). I always have the shoulder straps and hip belt facing up - otherwise the straps, hip belt and back of the pack are soaked, and then at the portage, so am I.
That position makes accessing a traditional pack’s pockets from the seat of the solo very difficult, even impossible.
So my design centers on accessibility from the wrong/other side of the pack. Things like binoculars, raingear, snacks, water, headlamp, headnet, knife, tiny tackle box, compass, sunglasses, sunscreen, etc. are all easily reachable while paddling or portaging.
First, more business for RipstopbytheRoll, and I am using their HyperD 300 fabric, which is 3.9oz/sq yd. Still light, but waterproof and certainly heavier-duty than the 1.6 oz/sq yd SilPoly I used for V1.
As before I am hoping to build a pack that is:
*Very light - empty pack weight around 20 ounces.
*Short height - anything above the shoulders may interfere with my 4.5 oz solo yoke (Build thread here )
*Waterproof
*About 44L for the pack body…plus some pockets. (slightly smaller than V1)
*Padded hip belt
*Comfortable enough at 25 - 30lbs
*Accessible pockets - both for portaging but also while in the canoe
* New: Map Pocket, just a simple sleeve to quickly stow my map during the portage.
V1 dimensions of the main pack body were: 24" high x 14" wide x 9" deep.
V2 size will be 24" x 14" x 8".
Unchanged from before (text copied almost verbatim from my post on V1:)
That last item (the accessible pockets) is tricky. Traditional pack pockets are:
1) on the sides (and if they zip it is on the pocket’s top)
2) on the top/lid
3) on the ‘front’ (the side away from your back)
When I drop my pack in the canoe I put it behind me (dog goes in front). I always have the shoulder straps and hip belt facing up - otherwise the straps, hip belt and back of the pack are soaked, and then at the portage, so am I.
That position makes accessing a traditional pack’s pockets from the seat of the solo very difficult, even impossible.
So my design centers on accessibility from the wrong/other side of the pack. Things like binoculars, raingear, snacks, water, headlamp, headnet, knife, tiny tackle box, compass, sunglasses, sunscreen, etc. are all easily reachable while paddling or portaging.
First, more business for RipstopbytheRoll, and I am using their HyperD 300 fabric, which is 3.9oz/sq yd. Still light, but waterproof and certainly heavier-duty than the 1.6 oz/sq yd SilPoly I used for V1.
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
02/27/2022 09:44AM
I have a decent start on it but I think this will take several weekends.
I am planning on making the shoulder straps myself - last time I sourced those pre-made.
Here, I am starting with the map pocket, which was a late addition to V1.
The side strips are HyperD 300; the black mesh is RSBTR's "Pocket Mesh" (low stretch) and the light grey is a very stretchy pocket mesh from AdventureExpert. I've put some elastic under tension in a thin channel at the top. I've also learned about the wonderful world of Stretch Stitches...
I am planning on making the shoulder straps myself - last time I sourced those pre-made.
Here, I am starting with the map pocket, which was a late addition to V1.
The side strips are HyperD 300; the black mesh is RSBTR's "Pocket Mesh" (low stretch) and the light grey is a very stretchy pocket mesh from AdventureExpert. I've put some elastic under tension in a thin channel at the top. I've also learned about the wonderful world of Stretch Stitches...
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
02/27/2022 10:00AM
Next, the large/tall zippered side pocket. Spreader bars (for my ridgerunner hammock) and/or tent poles, stakes, etc. find a nice home in this pocket.
V1 has this pocket and it is great. Building it the same, other than slightly smaller. V1 was 18" high, 9" wide and 2.5 inches deep. Frankly so big the bars/poles often rattled about.
V2 pocket will be 18 x 8 x 1.5".
Zipper:
Pocket coming together:
V1 has this pocket and it is great. Building it the same, other than slightly smaller. V1 was 18" high, 9" wide and 2.5 inches deep. Frankly so big the bars/poles often rattled about.
V2 pocket will be 18 x 8 x 1.5".
Zipper:
Pocket coming together:
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
02/27/2022 04:33PM
Sides, front, back connected.
Still need to deal with the top, bottom, and then the most complicated parts - shoulder straps & hip belt.
I need some additional fabric for those last two - should be here this week.
Still need to deal with the top, bottom, and then the most complicated parts - shoulder straps & hip belt.
I need some additional fabric for those last two - should be here this week.
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/06/2022 06:59AM
Put in a handful of hours on this yesterday, entirely focused on the hip belt.
I decided to change the hip belt pocket dimensions slightly (from 7x6.5x3 to 8x6x2.75") but the capacity is virtually the same. Those are pretty big hip pockets for a backpack.
But more importantly, I decided to permanently attach the pockets this time (V1 pockets are removable).
This makes the build more complex, for sure.
I decided to change the hip belt pocket dimensions slightly (from 7x6.5x3 to 8x6x2.75") but the capacity is virtually the same. Those are pretty big hip pockets for a backpack.
But more importantly, I decided to permanently attach the pockets this time (V1 pockets are removable).
This makes the build more complex, for sure.
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/06/2022 07:06AM
The hip belt will also be taller, which hopefully means a little more support & comfort while carrying. We'll see.
The lack of sewing expertise is still obvious, but I have learned and the 'finish' level of what I am making is definitely an improvement over V1. I'm a better sewer (not saying much), but another helping factor is that this fabric has less stretch than my V1 fabric, so it is easier to keep seams aligned and neat.
The lack of sewing expertise is still obvious, but I have learned and the 'finish' level of what I am making is definitely an improvement over V1. I'm a better sewer (not saying much), but another helping factor is that this fabric has less stretch than my V1 fabric, so it is easier to keep seams aligned and neat.
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/06/2022 12:38PM
Thanks for the compliment! This is coming together really well; in terms of build quality it is definitely the best thing I've ever made. But I am sure Dan Cooke would not hire me to sweep his floor. :-)
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/06/2022 12:42PM
For fun, some weights...
Hip belt is a hair under 5oz.
Main bag w/ side pockets (still have not attached the top) is tracking to be about 9oz.
So if I can bring the shoulder straps in at 6oz or less, the finished pack should be at or under the target 20oz.
Hip belt is a hair under 5oz.
Main bag w/ side pockets (still have not attached the top) is tracking to be about 9oz.
So if I can bring the shoulder straps in at 6oz or less, the finished pack should be at or under the target 20oz.
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/06/2022 04:32PM
YetiJedi: "Very impressive! Lightweight, should be very durable, and DIY...the triple crown. Would like to hear how it goes on your next trip and, if successful, where they will be sold!"
Thanks - but the only way I could sell these is if I paid someone else to build them! That said, I am looking forward to using it for its intended purpose.
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/06/2022 04:34PM
Made the attachment for the webbing that connects to the bottom of the shoulder straps, and attached to the bag along with the hip belt. Lightly tacked together for now, in case yet more seams need to be ripped.
Seam ripping - now that is something I have become very good at...
Seam ripping - now that is something I have become very good at...
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/06/2022 05:17PM
Painful error. Not literally, but...I failed to compensate for the thickness of the foam, and the padded area of the shoulder straps will be too narrow.
Snip. Snip.
Going to splice in wider fabrics...
Snip. Snip.
Going to splice in wider fabrics...
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/12/2022 11:13AM
Back at it & hoping to finish this weekend.
So I have reconstructed the shoulder straps. Probably would have been easier just to start over.
I did get some Cordura 1000D for the top of the shoulder straps where a yoke could wear/abrade them.
Next up will be the pockets on the vest part of the straps.
So I have reconstructed the shoulder straps. Probably would have been easier just to start over.
I did get some Cordura 1000D for the top of the shoulder straps where a yoke could wear/abrade them.
Next up will be the pockets on the vest part of the straps.
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/12/2022 04:56PM
Main pockets for the vest straps are on. Each side has a flat pocket (one side zippered, one side black mesh with a velcro closure) on top of a larger zippered pocket.
I'm going to add another smaller one above these.
Tedious stuff. Lots of time for what seems like small results.
I'm going to add another smaller one above these.
Tedious stuff. Lots of time for what seems like small results.
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/12/2022 08:01PM
Vest-style straps are sort of done...at least the lower parts, including all pockets.
Tomorrow I need to add foam to the shoulder straps, connect the shoulder straps to each other, connect to the pack, and attach the pack lid.
Then check the shoulder straps, hip belt and even lower strap attachments for length and angle before securing more permanently.
This will be a pack for me and anyone my size - all others are out of luck, I am not building in much adjustability!
Tomorrow I need to add foam to the shoulder straps, connect the shoulder straps to each other, connect to the pack, and attach the pack lid.
Then check the shoulder straps, hip belt and even lower strap attachments for length and angle before securing more permanently.
This will be a pack for me and anyone my size - all others are out of luck, I am not building in much adjustability!
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/13/2022 10:28AM
Swiss-cheesed some minicell foam for shoulder pads.
nb: Minicell forms so very well...except one way: slicing into uniform thicknesses is really difficult. Should have just bought a sheet of the desired thickness. Oh well.
nb: Minicell forms so very well...except one way: slicing into uniform thicknesses is really difficult. Should have just bought a sheet of the desired thickness. Oh well.
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/13/2022 01:29PM
Thought I would finish in about an hour, but I am short one #3 waterproof zipper for the lid. Given lead times from RSBTR, I'm likely on a two week break.
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
03/19/2022 06:29PM
Final weight 20.4 oz...
Spacious vest pockets drove the weight up, but I really like having lots of little storage places at hand.
I am pretty excited to give it a spin when we have water in its fluid form again.
Spacious vest pockets drove the weight up, but I really like having lots of little storage places at hand.
I am pretty excited to give it a spin when we have water in its fluid form again.
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
01/19/2023 10:19PM
sns: "Final weight 20.4 oz...
Spacious vest pockets drove the weight up, but I really like having lots of little storage places at hand.
I am pretty excited to give it a spin when we have water in its fluid form again."
Job well done! How did it perform for you this past liquid water season?
Nothing is softer or more flexible than water, yet nothing can resist it. - Lao Tzu
01/27/2023 05:54PM
mcspin50: "sns: "Final weight 20.4 oz...
Spacious vest pockets drove the weight up, but I really like having lots of little storage places at hand.
I am pretty excited to give it a spin when we have water in its fluid form again."
Job well done! How did it perform for you this past liquid water season?"
Very well, thanks for asking.
The pack visited the Quetico three times last year, and I had no complaints. Bit of fun deciding what item went in which pocket, with numerous changes along the way.
No signs of wear on the material so far.
Pack was an essential part of the single-portage strategy (group adult trip, trip with the kids and a solo trip were all single-portaged).
"I don't care what you believe. I care what you can prove." -Philosopher & Mathematician JJJ
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