Showing posts with label DIY. Show all posts
Showing posts with label DIY. Show all posts

Friday, December 4, 2015

My gear this winter


Here is what I packed for my most recent hike.  This is my set up for an all day hike in the rain in the winter.

For warmth,I included rain coat and pants, hat, glove and extra socks.  For extra insulation I also pack a fleece vest and a fleece jacket.   On my feet I wore gortex boots to keep them warm and dry.  I wore two layers of socks, very thin sock with a warmer sock over it.  The thin sock keeps me from getting blisters.

   I also packed two snap type reusable hand warmers and a USB handwarmer / flashlight / battery.

For navigation and safety I packed my Garmen GPSmap 60csx with several maps loaded and some way points to mark my intended route.  I also packed my Delorme inReach satellite messenger.  I included extra batteries for my gps and my headlamp and USB cords that I can use to charge my inreach or power my GPS with my USB handwarmer.

I also packed a first aid kit, and evernew water bag and a sawer squeeze full sized filter.

Also in my kit is a titanium mug, alcohol stove, widescreen, BIC lighter and a coffee mix.  The bottle with an orange "X" on the top holds my fuel.  I love to have a hot drink during a cold and rainy lunch break, so I always have my little kitchen kit with me.

New this year is my 8.5 ounce cuben fiber tarp.  The tarp is 7X9 and the weight includes, two stakes and string to pitch it with.

For lunch I just grabbed a bunch of stuff off the shelves of the local expired food store in Shelton.    It was all expired but it all tasted okay.  I only wish the jerky had not been so sweet.  I needed more savory and salty stuff.

I pack my botany hand lens everywhere, it has a blue lanyard in the picture.  Also in my pack is some flagging in case I go off trail.  I carry a small swiss army classic knife for tweezers and scissors.  If it's mushroom season then I pack a bigger knife.  If I think there will be any trouble with people on my hike I also carry a weapon.  My weapon is not a firearm.

All of this stuff goes into my homemade pack pack the Mossy Mom 2.0


Friday, November 13, 2015

My new backpack is ready for the trail

You can just barely see the ice axe loop at the bottom. I also
added a velcro loop to hold my trekking poles.
I finished up my new daypack last night.  Now I have to wait for the storms to pass before I can test it on the trail.  This pack has a nice tall left outside pocket to hold a water bottle firmly. and the right pocket is high enough to completely swallow my GPS.  I also sewed in a extra pocket inside of the left pocket to hold my pstyle.  I was hoping to be able to access it with my pack on but the pocket is just a bit to tall for that.

This pack cost me about $8.00 to make as the only materials I bought for it were elastic, thread and sewing machine needles.  I still have lots of elastic and thread and two needles left that did not get used.

I don't think I have enough material to make a third pack from my old tent rain fly, so I may have to buy fabric the next time I make a new pack.

I'm sure the first few trails tests will show any seams that were not formed properly.  I found the first bad seam before it even left the house and it is fixed now.

I have not weighed my new pack yet.  I'm guessing it weighs about 10.8 ounces.





Sunday, November 8, 2015

I am Making a New Backpack


I'm really happy with the backpack that I made for myself a year and a  half ago. But there are a few things about it that I would like to change, so I'm making a new pack.  The main problem with my old pack was actually a problem with my sewing machine.  My machine was a pile of junk and it was not heavy duty enough for the job.  Because my machine was such a broken down hunk of junk I was not able to sew my pockets into the main seams of my pack.  I had to sew all the pockets onto the outside.

That made weak spots at the top corners of every pocket.  The I had  a lot of other problems with pockets too but after many trips back to the sewing machine I have figured out a good design.  You see I did not simply sew my own backpack. I DESIGNED MY OWN BACKPACK.  I did not have a pattern to go off of, or any directions to follow and I'm not much of a seamstress   I got a "D" in home economics because I failed the sewing project.  Add to that the my sewing machine was broken and I did not even know it, it was amazing that I managed to make anything I could take hiking.

The feed dogs on my old machine were broken and I did not know that a machine was supposed to feed the fabric.  I thought it was my job to pull the fabric through the machine and this was with a machine that only had two speeds; fast and insanely fast.  When I realized that my machine was broken I took it to a shop that could not fix it.  They offered to sell me a new used machine instead.  Okay, I know what you're thinking, they were just trying to up-sell me.  But no, this shop was an honest shop.  The found and old sturdy Kenmore machine and sold it to me for what they would have charged me to repair my machine.

I think I paid them $50 for it and it was tuned up and perfect for my needs.  I'm so happy with my new sewing machine.  Sewing is actually kind of fun now.  Since then I have inherited my Mother's sewing machine but it is not as good as my old Kenmore other than the fact that it has a free arm.  So I'll keep the free arm machine for sewing clothes and the Kenmore for making backpacks.

My new backpack sewing project is going very smoothly so far.  It's going suspiciously well.  My machine is behaving and I've only had to use the ripper a couple of times.

I have cut out all the pieces and I have sewed the pockets into place.  All I have left to do is sew it all together and add a couple of finishing touches to the shoulder straps.  I anticipate that I will be able to sew it all together without too much trouble.  The parts seem to fit well, and there is lots of room for error with a backpack and a one inch seam allowance.

Here is what I have done so far.  The rest will have to wait until I get back from Kirkland.

I started by cutting out the side panels.  I used the grid mat to help me make them square

4 panels and 3 outside pockets cut out

decorative trim and loops to hold bungee cord on side panels

Two pockets that my sit pad will fit into. This part of the pack will go against my back

Pockets have been tacked into place.  Velcro loop to hold trekking poles
and green loop to hole ice axe have been added

All pockets and panels done, including loops to hold in internal pocket
I'm going to use the internal pocket from my ULA pack.
Shoulder straps are on the far right.  I need to cut the foam to go in them and
then sew them to the top of the pack and sew cord to the bottom of the pack.
I don't have the little plastic parts I need to hook the to parts of the shoulder straps
together, so I will have to buy that.

All of the material for this pack has been upcycled. Once again I am using the old rainfly from my 4 season tent for the pack body.  I'm using an old shirt to hold the sit pad and to line the back of the shoulder straps.
The black pockets are made from a huge bag that I paid $1.00 for and have already used for pockets on my current pack.  All I have bought for this project is new sewing machine needles, thread and elastic.






Monday, June 8, 2015

Update on my homemade pack

Version 1.0
Verson 1.1


Almost done
Version 1.5 the most current version

Bottom green panel that holds my sit pad is new today, made from an old tshirt





I've been using my home made day pack for slightly more than a year now and it is still going strong. I have replaced every external pocket except for one. I just replaced the lower pocket that holds my sit pad. All the replacement pockets are strong and holding well. The first set of pockets were just a poor design.   I have also torn the main seams apart and redone them twice.  Now the pack is sturdy and does not need repairs.


 I guess I have taken this pack on about 70 day hikes at this point.






 This pack was made from 95% recycled material. The green fabric is an old tent, the bright green is an old shirt, the black pocket is a bag I bought at Nifty Thrifty. Most of the webbing is recycles from old projects. The only new materials I bought for this were the thread, the elastic and the green bungie cord on the back.

Sunday, February 8, 2015

Update on my homemade daypack

This is what my pack looks like now:


This is what my homemade day pack looks like now.  I've replaced the front pocket and both side pockets with stronger material.  I also made a new interior pocket that is lighter.  The interior pocket came off a couple of times then I attached it to the strip of webbing that holds my shoulder straps it place and it has stayed put ever since.

I am very happy with my pack because it was built just for me. It has all the features that I want and it is exactly my size.  I had to repair this pack about every other month at first due to some design flaws. Now it does not need as much repair work and  I know how to make a stronger pack next time around.

Things I would do different include sewing the pocket edges into the body seams instead of outside of the pack.  I knew that was the right way to do it from the start but my old sewing machine could not sew through 4 layers at once.  I would also use stronger material to hold the sit pad in place, it rips from time to time and has been patched up with duct tape.

I bought a new sewing machine shortly after I made this pack  sewing machine shop was amazed that I was able to make any outdoor gear with the crappy machine that I had.  My new machine cost me just $75 but it is a tank.  My old machine was like a 2 stroke engine, it revved way to fast and was hard to control.  My new machine is like a 4 stroke engine or maybe even a Caterpillar truck engine.  I can have total control over the speed from super slow to almost too fast.

For years and years I suffered with my Dressmaker brand machine.   This new old Kenmore machine makes sewing so much easier.

One of these days I will make myself a new day pack with my new machine and my new skill set.  But for now I just love my current day pack too much to retire it.

I am really enjoying the freedom of not having a hip belt on my day pack.  I like to be able to just shrug the pack off when ever I want to.  At first I did not like the extra weight on my shoulders but now I never even think about it.  The only bad thing about no hip belt is that when I am brush crashing if I lean over too far the pack can come off over the top of my head.  Keeping the shoulder straps tight will prevent that though.

Tuesday, December 16, 2014

The YACC Stove Original Directions

Ray Garlington who is the author of this post has given permission to grab it and his photos from the wayback machine and post it here.  I think this is the easiest pop can stove one can make and this post is what really got me started with making my own stoves.  I like this stove because it is easy to make and it saves extra weight because it serves as a pot stand.  This is also a very efficient stove.

When I first starting trying to make a pop can stove all the directions I found were too complicated and I almost gave up and then I found this page that changed everything for me.  I still make my own stoves and I only make simple ones like this.

Thanks Ray!


The Garlington YACC Stove
4/6/2004



Yet Another Coke Can (YACC) Stove

Got 5 minutes, a coke can, and a pair of scissors? If so give this little stove a try. It is easy to make, and uses only one can. Also, the pot sits right on top, so it doesn't need a  pot stand. Just add a piece of aluminum foil for the wind screen & you are good to go. The YACC stove can raise a pint of 65*F water to 135*F using 1/4 oz of alcohol when air temperature is around 65*F. I have found this sufficient for my lightweight 'cooking' needs. A 4oz supply of alcohol lasts me for 16 stove firings, which equates to 4 gallons of 'hot' water. Of course, if you need more heat, you can add more fuel.

The stove was inspired by the Antigravity Gear stove (uses two cans) and "The One Can K.I.S.S. Soda Can Stove" by DeoreDX on the TLB Forum. I liked the idea of using just one can, and wanted construction to be as easy as possible. The YACC stove can be made quickly with just a pair of scissors.



Here's how to make it

Obtain an aluminum soda can.

Remove the opening tab from the top, and tear the top out with a pair of pliers.


Mark the side of the can 3/4" up from the bottom. Flip the can over and mark the side of the can 1 1/2" from the top.

Using a pair of scissors, cut the can in half
Now, carefully cut along the marked lines. If your marked lines are on the 'thick' side, cut the bottom along the outside of the line (thus making the bottom slightly larger).
Take the top section and cut slits every 1/2" from the cut edge to just below the shoulder of the can top.
Push the tabs slightly toward the center and slide the top section into the bottom section. Push the top (carefully) all the way down into the bottom. The tabs of the top will follow the can bottom until they jam up against the domed part of the bottom. As the shoulder of the top starts to go under the cut edge of the bottom, look for bulges that might tear the bottom and push them inward with the flat side of the scissor's blade. When fully seated, the top's shoulder should be slightly under the bottom lip. None of your slits should be visible from the top. (If they are, you will need to cut another top.) Hold the can together and roll the cut edge of the bottom slightly inward over the top's shoulder to hold the stove together.
If the details above sound too tedious, just push your two stove halves together. At first, your stove will spring up so that the top slits are exposed. Don't worry, because after you light the stove, you put the pot on, which will compress the stove anyhow. After using the stove a few times it will stay compressed (particularly if there was a little soda left in the bottom).

Theory of Operation

OK. Now that you see how it goes together, how does it work without any gas jets? Well actually, the jets are there, but hidden under the cut-edge of the stove bottom. All those cuts in the top allow gas to pass through which find their way out the small gap between the can top and bottom. So, in the end you have a two wall (well sort of) stove that is pressurized (again, sort of).

Operating Instructions

This stove requires preheating to the point where flame comes out the seam. Details:
  1. Pour the fuel into the stove body. Denatured alcohol, Heet, everclear, and similar products are good fuels. 1/4 oz of fuel will burn for about 3 minutes.  Note: It has been reported that the stove will not burn on rubbing alcohol.
  2. Position the wind screen and light the stove by holding a flame above the large hole.  Watch out because the stove lights easily and the flames are nearly invisible at first.
  3. Hold your pot about an inch above the stove until flames exit the side of the stove (about 15 seconds). When that happens, immediately position the pot on the stove.

Adjustments

Variations in building technique may cause you to end up with a stove that has problems.

Stove burns too fast

If you think your stove is burning too fast, you can extend the burn time by making the stove a little tighter. Separate the stove halves and flatten all the slits as much as possible. When you reassemble the stove, make sure that none of the slits are visible (i.e. make sure they are hidden in the bottom of the stove). If the slits are showing, even though the top is pushed as far into the bottom as possible, remove the top and cut off a little from each of the tabs. When you reassemble the stove, the top will go further into the bottom, hiding the slits. A tighter stove makes it harder for the vaporized alcohol to get out, so that burn speed will be reduced. The slowest I have been able to make the stove burn is for 11 minutes on 1/2oz of fuel.
Stove burns too slow
It your stove burns to slow, or fails to ignite on denatured alcohol, you need to loosen the gap between the top and bottom halves. Push a needle into the seam between the two halves in about 5 spots spread evenly around the can.

Burping Stove

The most troublesome problem reported seems to happen when a relatively large fuel load is added and the stove gets too hot.  If this happens, liquid alcohol is forced out of the stove onto the supporting surface where it will ignite.

Burping stove repair #1 (Posted by Parkinson1963 of the Lightweight Backpacker

"I figured out the burp is cause by a build up of pressure in the stove between the the two walls. The solution is to bend about four of the fingers into the open part of the can slightly, making these slits slightly wider. This allows the presure between the walls to be less, and less likely to burp. After six consective burns with one ounce of fuel each time, no burps.
This is the best stove so far two cups to full boil on 3/4 ounce of fuel, no pot stand only need aluminum foil to make a windscreen. Fantastic!!!"

Burping stove repair #2 (Posted by Parkinson1963 of the Lightweight Backpacker): 

"I discovered another easier way to eliminate the burping problem. Simply make four holes just below the top rim I used the awl on my swiss army knife. A tight very carefully made stove plus the four holes made for a perfect stove with no burping."

Burping stove repair #3 (Ray):

Using a sharp push pin, punch a row of holes around the shoulder of the can. Punch them above the seam between the stove bottom & the top. They vent directly into the center of the stove and keep the internal pressure low. They have the appearance of the gas jets on the usual pepsi stove, but when the stove is operating, it looks like the flames are emanating from the seam.

Enhancements

Here are some other construction ideas you might like to try:  add an interior wall to the stove, cutting the top out cleanly.

Add an interior wall to the stove

If you do this you have, in essense, the anti-gravity design built with one can, but without the careful sealing. It takes a few extra minutes, a stapler and a needle to do this. Here is what you need to do:
  • When you cut the can in half, be a little more careful and cut closer to your 'top' line. Your objective is to leave enough aluminum from the center of the can to cut a strip 1.25" wide for the complete circumference.
  • after cutting the top and bottom pieces, carefully cut a 1.25" wide strip from the center section of the can. Take the time to draw lines and cut carefully.
  • take this strip of aluminum, fashion it into a cylinder and slide it up into the groove inside the top of the can.
  • hold this strip together with your fingers, pull it out of the top, and staple it together about 1/4" down from the top.
  • Take the strip, and use your scissors to cut 1/4" long slits, about every 1/4" around the bottom of the strip (the rim of the cylinder furthest from the staple).
  • Slide the strip into place in the top and assemble the stove. Push the top and bottom of the stove together as tightly as possible, then run the back of your scissors around the seam to make sure it is lying flat and there are no tears in the bottom.
  • Take a sharp pin and punch pinhole jets into the top about every 1/2" around the circumference of the stove, just above the seam.
  • With this modification, the stove burns longer with a more even flame. I get 4+ minutes from 1/4oz of alcohol and higher final water temps.

Cutting the top out cleanly (Posted by Rambler of the Lightweight Backpacker):

For me a can opener does not work well cutting out the top as it did when cutting out the bottom of the original pepsi can stoves. A 2" hole saw fits the can top ridge circle pefectly. Holding the saw cutter by hand rather than attached to a drill and then turning the can and drill in opposite directions by hand soon cuts out the top cleanly. However, it is best to use this method before cutting the can in half, ie. after removing the tab, the next step is to remove the top. A key instruction to a successful stove is to be careful to make the slits 1mm above the shoulder. Using the guiding line is a useful tip. Thanks to rgarling for an easy way to build an effective stove.
Comments from Tony Wong about his first YACC stove:  (sorry about the lost pictures....)

 I was quite pleased with my first attempt. I used a Pepsi can and followed your instructions. Here's a shot of the stove in action burning methyl hydrate (paint thinner grade).

// picture missing//


Some of the things I ran into/discovered.

  It took me some time to figure out how much a "quarter of an ounce" is as it's been a while since I measured volume in imperial units. I managed to find a graduated cylinder in both units and discovered a 1/4 oz is equivalent to about 7 millilitres. 

  In your instructions, I wasn't sure where to light the stove, in the big hole in the top or try and light vapours coming out the side. In the end I just lit the fuel inside the big hole in the top, eventually the stove started to work, so I guess that's the trick. Perhaps a worthwhile addendum to your web site instructions?

  Performance wise, 1/4 oz (7 ml) methyl hydrate heated one cup (250ml) tap water to point too hot to put fingers in. Sorry don't have a thermometer handy. I seem on the short side of max temperatures and burn times reported by others.

  I found a carpenters marking gauge made it easy to measure out and scribe lines around the can. The gauge has an adjustable fence, measurements on a ruler, and a scribing awl.

// Marking gauge picture missing //


  To cleanly cut out the top of the can, I tried a round hole saw, but found I wasn't making any headway in cutting the top off. Instead the teeth were scraping along the vertical surface where the top of the can meets the thicker rim of the can. But I discovered when I used a bent needle nose plier, that the hole saw had thinned the aluminum sufficiently where the can top meets the thicker rim and the metal tore away nice and cleanly. A bit of filing took the sharp edge off. Unexpected, but it worked out nicely.

  Initially, I couldn't get the two parts of the can to stay together. But after the first burn, it seems the paint and varnish on the top part of the stove gets burned off and the surface is less slippery. The increased friction seemed to hold the 2 halves of the stove together nicely without any other physical fastener. I didn't have any luck rolling or squeezing the circumference of the stove bottom to hold the top piece in place. I tried a circumference clamp all around the can, but I couldn't reduce the diameter of the outside can to hold the inside can. But after the first burn, it was no longer an issue.

 To get the slit length correct, I used a scrap strip of aluminum and inserted it into the can bottom and pushed it down until it bottomed out against the bulge in the can bottom, just like a slit in the top would do when the stove was assembled. I marked the strip at the top edge of the can bottom and used that to mark how long the slits needed to be. After assembly, some of my slits extended above the top of the bottom can--I must have cut the bottom can a bit too short. On the next stove, I'll cut the slits first, insert into the bottom can, and mark where I need to cut the bottom can off to ensure the slits are covered.

Thanks,
-Tony
Vancouver, BC Canada

Let me know how your stove works out. Reach me at rgarling AT yahoo DOT com
Thanks
Ray

Thursday, April 17, 2014

Final pictures of my completed daypack

I've tinkered with my day pack a little bit and now I am completely satisfied with it until I shred all the mesh. 

My home made hiking daypack is ultra light
I added some fabric to the back of the shoulder straps to help absorb and prevent sweating.  I also added some green shock cord that I actually paid for.

The final cost for my pack was about $8.00 in materials and thread.  The final weight is 11.5 ounces. Not bad.  I could have gone lighter if I had actually paid for any of the fabric but 11.5 ounces is just fine with me.




Side view
 
Final bit of tinkering added material to the back of the straps
to both absorb and help stop sweating.  I did this with my
new sewing machine so the lines are pretty straight.
 
Final weight 11.5 ounces
Visit this blog post to see how this pack was constructed.

While making my pack I learned that my sewing machine is a total piece of garbage.  My machine was so bad that the shop offered to sell me a different machine for $45, that is $5 less than the price of repairing my garbage machine, but even then the reverse would have been non functioning.

I told that shop that I would like to have a slight upgrade instead of the same model so they sold me a nice old Kenmore 158 for $75.  The older sewing machines are better then anything you can buy in the store as they were made to last.

The Kenmore has been serviced and it runs great.  I love it!  I look forward to doing more projects now that I have a sewing machine that actually works.


My new used sewing machine

Friday, April 4, 2014

What food to pack for backpacking with a child


  I'm hoping to take my daughter on a four night backpacking trip.  This will be our longest trip yet and she will have to carry some of the food.

Here is what I have packed for our trip:

14.5 pounds of foods for 4 nights out 3 breakfast 4 lunch and 3 dinners


On the top row lunch and snacks from L-R:
  two packages of wheat tortillas with a one pound of peanut butter sitting on top of them.   14 power bars for my daughter

Next row down is dinner and beverages from L-R:
coffee and cocoa powder in little bags, One pound of sugar, some random peanuts that I tossed it at the last minute.  Bottle of hot sauce, bottle of "olive oil",  Dinner number 1 dehydrated potato with home dehydrated ground beef and squash.  Dinner number 2 red coconut curry with chicken and beef and rice.  Dinner number 3 Green Bean threads with dehydrated tomato sauce, lentils and a tiny bit of meat.   I need to add more meat to it.

Bottom row: Breakfast and snacks, L-R Emergen C power, Ginger cookies for my daughter, 4 bags brown rice,  4 bags of Powdered whole milk, Power bars for me.  Breakfast will be instant brown rice with milk and sugar and dehydrated raspberries from my garden.  The raspberries are in the dehydrator right now.

I have not added up the calories here, but I'm shooting for about 3,000 per day for me and 3,500 per day for my daughter.  I expect that I will be giving her some of my power bars.

Olive oil will be added to all the dinners to boost the flavor and calories.  I will be adding hot sauce to all my dinners as well.  We will each have two cups of milk a day.  One cup will be in the breakfast and the second cup will be mixed with cocoa and sugar for hot chocolate.  I'll be having instant coffee mixed with cocoa, sugar and powedered milk in the morning and after noon.

I will be cooking 2-3 times per day.  Breakfast, dinner and hot drinks will be cooked, so I will need to bring a fair amount of stove fuel.  All cooking will be done on an alcohol stove with a titanium pot.  We will be eating out of metal pots too.  I am working to get away from using plastics, especially for hot food storage.  Next trip I may go back to storing all my uncooked food in paper bags.  We are expecting close to freezing temperatures for at least one night of the trip so hot food is needed.

The power bars were all purchased at the price of 4 for a dollar because they are slightly past their sell by date.  You can see that there are no commercial prepared "backpacking" foods in this picture.  I'm a thrifty mom  with MSG sensitivity, so I don't go for Mountain house or Pakit (MS)Gourmet.

Thursday, March 20, 2014

My new Daypack


For the last several weeks I have been working on making my own hiking day pack.  I designed this pack to be a hybrid between my last two hiking backpacks, but with a roll top closure and a removable internal pocket.  This pack is smaller than my last day pack and hopefully stronger than my golite dawn pack.


DIY home made hiking day pack

The roll top closure will allow the pack to expand enough to carry two gallons of mushrooms or extra gear in the winter time.

I'm really not very good at sewing, especially by machine.  I learned so much about my old sewing machine and myself while making this pack.

Later I may post a step by step guide but for now I will just post a few pictures of my new pack and the process of making it.

I paid $5.75 for the materials to make this pack.  How did I do it so cheaply?  I recycled!  Oh wait, the word is actually upcyled.   The pack body is made from 72 denier ripstop fabric salvaged from the rain fly of my four season tent. (Eureka outfitter assault 4) The mesh I already had on hand and all the hardware such as clips was salvaged from other gear that I have tossed over the years.  I took the shock cord off two older day packs.

The biggest expense was the thread.  I used an entire 150 yard spool of thread and had to buy more thread before I could finish the project.  Most of the thread I bought is left over and can be used for other projects.  Here is my cost break down, not counting all the left over thread I have.

Thread $3.00 (Wal-mart)
Batting $.75 (from thrift store)
Elastic $2.00 (Wal-mart)

Final weight of my pack is 9.7 ounces, including the foam pad.  It would be lighter if not for the super heavy recycled oops, I mean upcycled zipper on the internal pocket.

After just a quick spin around town I found that I needed to redo the top stitching on all my pockets because the thread was breaking.  With that problem fixed I think this pack is ready to hit the trail.


Step one finally cracking open the owners manual for the machine that I
have had for 28 years.  Note that the spool of thread is in the wrong position here.
It turns out that the needle was also in backwards and the feed dogs
were not working at all.  I had to take my feed dogs a part twice to get them working.
Design took weeks

Tested my design with scrap fabric first
Front panel with pocket sewn on

The back and side panels with the side pockets sewn on




Side pockets, pad holder pockets and bottom of shoulder straps sewn on
 
 
Making the shoulder strap tops


Shoulder strap tops are ready to be sewn onto pack body
 all that is left after that is to sew the pack body together
and finish up the roll top closure


Time to load it up and take it for a spin around town
Next I need to test this out on the trail
 
upcycled zipper  on internal pocket is a bit heavy
Velcro inside pack to
attach pocket to

Velcro attachment on back of pocket


Update after taking the pack around town I redid the stitching on all the external pockets because the threads were popping. I thought I had fixed the problem by doing a zig zag stitch through the elastic.
 
 After taking the pack on a ten mile day hike some of the zig zag stitching was coming out on two of the pockets. I think my machine did not stitch all the way through the elastic or the thread is too weak.

I have now added very thick elastic (a bigger target to hit with my sewing machine) and I have both machine and hand stitched the elastic to the tops of the mesh pockets. I used much stronger thread for the hand stitching.   I also added reinforcement patches to the top of the front pocket on the inside.

I don't really understand why my thread was popping with a zig zag stitch.  Was the thread too week or did my machine have a problem?  My sewing machine is in need of repair.  The feed dogs hit the pressure plate and there is no way to adjust them that I can see.  It sews okay but after enough banging the feed dogs get loose and I have to tighten them up again.  They get loose due to hitting the pressure plate on the top of every stroke.  I don't know what the solution is short of filing bigger holes into my pressure plate.
Now with wider elastic and narrower shoulder straps
 The pack body and the shoulder straps held up just fine on my hike.  It was just little problems with the pockets that bothered me.

When I took this pack on it's first day  hike I carried my old Golite dawn pack inside of it as a back up in case of catastrophic pack failure.  But there was no catastrophic failure and I am now certain that this pack is trail worthy.
 
I always carry a needle and thread in my first aide kit so I can do field repairs to any of my gear.  Maybe I will add a bit more thread to my kit, but I don't think that I need to carry a back up pack anymore.

 
I also don't think this pack will need a hip belt.  Sure there is a bit of extra weight on my shoulders with no hip belt, but the freedom of no sternum strap or hip belt makes it so easy to shrug the pack off.  I think that freedom to shrug the pack off and the extra freedom around my hips with no hip belt make up for the extra strain on my shoulders.
 
One other adjustment I made to this pack was to cut the should pads in half lengthwise.  They were way too wide and were rubbing too much.