Michael Turner
Immediate recommendation: for single-day outings pick a 25–35 L daypack; for overnight trips select 40–60 L; for multi-day trips with stove, fuel and fuel-heavy food plan on 60–80 L. Aim for a loaded mass that stays near 20–25% of your body weight for comfort, rising toward 30–35% only if you are conditioned and the route demands it.
Fit matters more than brand. Measure torso length from the prominent vertebra at the base of the neck (C7) down to the top of the hip bones (iliac crest) and match that to the pack’s torso-adjust range. The hip belt should transfer roughly 60–80% of the load onto the pelvis; it should be at least 10–12 cm wide and sit squarely on the iliac crests. Test fit with 8–10 kg loaded first, then repeat with predicted full load.
Frame choice depends on payload: frameless models work well under ~6–8 kg and shave weight; internal frames stabilize loads from ~8 kg upward; external frames suit very heavy, irregular loads exceeding ~25 kg. Fabric denier guides durability: 210–420D ripstop is light and adequate for most; 500–1000D Cordura for heavy-use, abrasive routes. Look for DWR coating plus included or integrated rain cover rated to fully enclose the pack – seam-taping on critical seams reduces water ingress.
Feature checklist to inspect before purchase: padded, articulated hip belt with tool/phone pockets; adjustable load lifters and sternum strap that slide vertically; hydration-sleeve compatible with 1–3 L reservoirs and dual hose routing; top lid or panel access vs. front zip for faster reach; compression straps to stabilize shifting weight; dedicated sleeping-bag compartment and removable lid for modularity; trekking pole and ice-axe attachments if snow or steep terrain are likely. Weigh the empty pack: under 1.2 kg is lightweight for multi-day, under 0.8 kg is ultralight for minimalists.
Final check: pack core items and walk 20–30 minutes on varied ground; adjust tension, hip belt and load lifters until the hips carry most weight and shoulder straps feel light. If pressure points, slipping, or persistent sway remain, try a different torso length or a different model – small geometry changes often solve fit problems faster than buying padding or accessories.
Match pack capacity to trip length, season, and sleeping system
Target capacities: 20–30 L for day trips; 30–50 L for 1–3 nights; 50–70 L for 3+ nights or winter trips. Add +10–20 L for bulky cold-weather insulation or full double-wall tents; subtract 5–10 L when using ultralight quilt + inflatable pad + tarp shelter.
Trip-length baseline (capacity vs typical gear)
- Day (20–30 L): water, light shell, snacks, first-aid, map/GPS, small camera. Typical packed volume 8–18 L; leave 5–10 L unused for layers and food.
- Overnight (30–40 L): 1-person 3-season tarp/tent (6–10 L), sleeping bag (8–12 L) or quilt (3–6 L), inflatable pad (2–6 L), stove + small fuel (1–3 L), food for 1 night. Packed volume ~25–35 L.
- 2–3 nights (40–50 L): tent 8–12 L, sleeping bag 9–14 L, pad 3–8 L, extra clothing (6–12 L), 2–3 days of food (3–6 L). Packed volume ~35–45 L.
- 3+ nights or winter (50–70 L+): double-wall tent or large tent 10–16 L, winter sleeping bag 12–20 L, bulky puffy jacket 6–12 L, stove + larger fuel supply 3–6 L. Packed volume often 45–65 L; choose capacity with headroom.
Season, shelter and sleep-system adjustments
- Winter: add 10–20 L for insulated sleeping bags, thicker pads, mitts and extra layers; fuel volume increases for melting snow.
- Quilt vs sleeping bag: quilts compress to 3–6 L; comparable down bags compress to 8–14 L. Switching to a quilt can free 5–8 L.
- Pads: foam pads 1–3 L volume when strapped externally; inflatable pads pack to 2–8 L–factor this when choosing internal capacity.
- Shelters: tarp + bivy compress to 3–6 L and allow smaller packs; double-wall freestanding tents require 10–16 L and often push you to larger volumes.
- Clothing: puffy jackets take 5–12 L; shell + insulating midlayer combination packs smaller than a single heavy jacket–use garments’ stuff-sack volumes to calculate.
- Food and water: plan 1–2 L food volume per day per person and 0.5–1 L water storage (add fuel for remote trips). Include these in final volume tally.
Quick method: pack all items into their stuff sacks, measure combined volume (liter markings or by displacement), then select a carrier with ~15–25% extra internal volume for compression, reorganization and unexpected items. If measured volume exceeds capacity, reduce shelter/sleep-system bulk or step up one size class.
Measure torso length and fit the hip belt right
Measure torso length standing: push your head forward to expose the C7 vertebra (the most prominent bump at the base of the neck), then measure straight down the spine to the top of the iliac crest (highest point of the hip bone). Record in centimetres and inches–accuracy ±1 cm.
Use these size bands as a baseline: Short 38–43 cm (15–17 in), Regular 44–49 cm (17.5–19.5 in), Long 50–55 cm (19.5–21.5 in). If the pack/rucksack has an adjustable torso panel, set it to your measured length before tightening shoulder straps; fixed-frame models must match your band within ±1–2 cm.
Measure hip belt circumference around the iliac crest at its widest point while standing relaxed. Common hip sizes: S 71–81 cm (28–32 in), M 82–92 cm (32–36 in), L 93–102 cm (36–40 in), XL >102 cm (>40 in). Women-specific belts are narrower at the front and wider at the sides–prefer those when pelvic anatomy differs from male patterns.
Fit check with load: pack 10–15 kg (22–33 lb) for day loads or 15–25 kg (33–55 lb) for multi-day simulations. Close hip belt so the padded wings wrap over the iliac crests and the buckle sits centered over the pelvis; tighten the belt until most weight transfers to hips–target 70–85% of the total load on hips. Tighten shoulder straps only enough to bring the load close to the body, then adjust load-lifters at about a 30–45° angle to bring the pack frame into contact with your upper back.
Quick visual/function checklist: hip belt padding must contact the iliac crest along its full width; no bare frame edges pressing the lower spine; shoulder straps should allow two fingers between strap and collarbone; sternum strap sits 8–12 cm (3–5 in) below throat and stabilizes but does not carry bulk of weight; torso harness should not ride above the C7 point when loaded.
If unsure between two sizes, prefer the larger torso with an adjustable harness or a longer hip belt that can be trimmed; for fixed belts, select the hip circumference that allows at least 10 cm (4 in) of overlap after threading the buckle. For air travel with electronic gear packed near the top or hip area consult screening rules: are digital cameras scanned separately at airport security.
Decide between internal frame, frameless, and external frame for your load
If your fully loaded weight is under ~10 kg (22 lb) use a frameless or ultralight framed pack; for 10–20 kg (22–44 lb) pick an internal-frame model with load-bearing hip belt; for sustained loads above 20–25 kg (44–55+ lb) consider an external-frame system or a heavy-duty internal frame with rigid stays.
Frameless: typical empty weight 0.2–0.6 kg (0.5–1.3 lb). Practical load limit ~0–10 kg (0–22 lb). Pros: minimal weight, compact, simplest suspension, best for fastpacking and short overnight treks. Cons: limited stability with heavy or very bulky gear, minimal shape retention, less effective hip transfer.
Internal-frame (sheet, aluminum/steel/carbon stays): empty weight 0.9–2.5 kg (2–5.5 lb). Comfortable load range 10–20 kg (22–44 lb); some models handle 25 kg (55 lb) when properly packed. Pros: close-to-body center of gravity, superior balance on steep or technical trails, better torso-contouring and load-lifter integration for hip transfer (hip belt typically carries ~80% of weight). Cons: slightly heavier, less ventilation than open external frames, frame damage possible from overload or improper packing.
External-frame: empty weight 1.8–3.5+ kg (4–8 lb). Best for loads above 20–25 kg (44–55 lb) and for awkward, bulky cargo (fuel cans, game meat, large tents). Pros: excellent for heavy/irregular loads, superior back ventilation, easy to strap long items. Cons: increased bulk and wind drag, poorer balance on steep singletrack and scrambling, heavier overall system.
Frame materials and suspension notes: polymer frame-sheets and foam are lightweight and fine for loads up to ~12–15 kg; aluminum stays add 200–600 g and provide predictable bending for 15–30 kg ranges; carbon keeps weight down but risks brittle failure under point loads and is costlier. Load-lifter straps and a well-shaped hip belt matter more than a tiny difference in stay material for day-to-day comfort.
Practical selection by scenario: ultralight weekend or fastpacking with 4–10 kg → frameless or minimalist internal; multi-day treks carrying 12–20 kg → padded internal-frame with adjustable torso; mountaineering, portaging, or pack-outs over 20–30 kg → external-frame or expedition internal with rigid stays. Pack and test with your actual load before committing for a long trip.
Fabrics, coatings and rain protection for expected weather
For consistently wet conditions: prioritize fully waterproof pack bodies (Dyneema Composite Fabric or laminated X‑Pac VX series) with welded seams, plus a roll‑top dry sack for sleep system and a fitted rain cover that extends over the hip belt and lid.
Materials and coating specs
Lightweight/fastpacking: sil‑nylon or DCF (30–70D face fabric equivalence). Advantages: very low weight and absolute water resistance for the body fabric (DCF). Tradeoffs: lower abrasion tolerance, seams and attachment points need reinforcement.
General trekking: 210D–420D ripstop nylon with PU lamination and DWR finish. This combination balances weight, tear resistance and long‑term durability for multi‑day trips in mixed weather.
Bushwhacking/overland: 500D–1000D Cordura or ballistic nylon with heavy PU coating. Use these where brush, rock contact and pack hauling increase abrasion risk.
Coatings and laminates: PU coatings provide abrasion resistance and are standard for backpacks; silicone coatings add tensile strength but reduce abrasion resistance and complicate seam welding. Laminates with PET or X‑PLY (X‑Pac VX21/VX42) give waterproof face fabrics and reinforce structure without excessive weight.
Rainproofing strategy and field maintenance
Redundancy: combine a waterproof main fabric or welded shell with an internal roll‑top dry sack for sleeping bag/insulation; carry a fitted rain cover as immediate external protection. Do not rely on DWR alone in prolonged heavy rain.
Seams and closures: true waterproof performance requires taped or RF‑welded seams and waterproof closure (roll‑top or welded flap). Zippers, lash points and hip‑belt pass‑throughs are leak paths–use internal liners where contents must stay bone‑dry.
Maintenance and testing: test DWR by spraying fabric – water should bead and roll off; if it wets out, reproof with a spray‑on or wash‑in product (Nikwax TX.Direct, Grangers). Reapply after ~1–3 seasons of use or when beading fails. Repair torn coatings with appropriate patch kits or re‑lamination services.
Accessories and sizing: rain covers rated at the pack’s litre capacity plus 10–20% ensure coverage; choose covers with an elastic hem and dual cinch points so the hip belt and lid remain protected. Use separate waterproof stuff sacks for electronics and documents.
If you plan short, intermittent-weather trips where a compact shelter helps, consider a lightweight umbrella as added coverage – review options at best umbrella company netherlands.
Evaluate pockets, compression straps, and attachment points for your gear layout
Place the most-accessed items in external, fast-access pockets: hipbelt pockets sized ≈12×8 cm for phone, GPS, snacks; shoulder-strap pocket ≈10×6 cm for compass or small camera; dual side stretch pockets sized for 0.75–1.0 L bottles (max neck diameter ~7.2 cm).
Prefer one zippered security pocket (YKK or equivalent) with a lockable slider for wallet/documents (capacity 0.5–1 L) and a large front “shove-it” pocket with 6–10 L usable volume for wet layers or map storage. Use stretch mesh where drainage and quick access matter; use coated zip pockets for electronics and dry items.
Hydration sleeve should accept 1.5–3.0 L reservoirs, include a retention clip at shoulder height and offer at least two tube exit options (left/right and top) to suit tube routing. Measure inside sleeve height: minimum 40 cm for 2 L reservoirs to avoid kinks.
Compression straps per side by pack volume: 80 L – 3–4 straps plus lid compression. Use 20–25 mm webbing with quick-release buckles; straps should provide ≥1.2 m free length when routed externally so they can wrap a rolled sleeping pad (10–12 cm thick) or a 25–30 cm long tent pole bundle. Position straps at top and mid-body to control fore-aft load shift; lower straps stabilize base-bulky items.
Attachment points: at least 6 daisy-chain loops or vertical lash points on the front for carabiner modularity; two reinforced lower gear loops for ice axe/snow-tool pins with removable bungee tie-offs; dedicated trekking-pole clips on shoulder straps and elastic retention lower down. Hipbelt should include small webbing lash points for a bivy/knife sheath and low-profile tool attachment.
For external pole/tent pole carry, route poles under two compression straps and behind a lower gear loop to prevent vertical slip; for cylindrical items (tent roll, pad) use crosswise compression plus a center strap to reduce rotation. Use the front shove-it pocket only for items that tolerate compression and moisture; keep fragile gear in zippered internal pockets adjacent to the frame or central sleeve.
Layout checklist: hipbelt pockets for high-frequency smalls; shoulder strap for one-handed retrieval item; side stretch for water; zippered top/front for valuables; hydration sleeve sized for reservoir chosen; compression straps sufficient in number and length to secure external loads; reinforced lash points for tools and poles. Test the assembled configuration on a loaded walk to confirm no bounce, easy access, and that shoulder/hip straps and attachment points remain functional under tension.
Conduct a full-load fit test and fine-tune strap tension and weight distribution
Step-by-step full-load fit test
Load the rucksack to your planned base weight (include first 48 hours of food, full water for the day and stove/fuel), then perform adjustments before leaving the trailhead.
1) Fasten the hip belt so the padded pads sit squarely on the iliac crests; tighten until you can just slide two fingers between pad and pelvis. The belt should transfer roughly 60–80% of total load.
2) Clip shoulder straps and pull them snug to eliminate a gap between pack and upper back; aim for the pack body to be 2–5 cm from the top of the shoulders (not resting on the neck). Shoulders should only stabilize, not carry the bulk – target 10–25% of load on shoulders.
3) Set load lifters at a 30–45° angle relative to the torso and tighten until the pack’s top is pulled toward your upper back. The result: firm contact along the lumbar and thoracic regions without making the shoulder straps dig in.
4) Fasten the sternum strap at mid-chest height so arm swing is unrestricted; tighten just enough to prevent shoulder straps from splaying under load.
5) Tighten side compression straps until lateral movement is under 2 cm during a bounce test (hop in place three times). Secure external attachments last.
6) Validation sequence: walk 30 minutes on flat ground, climb 50 steps, descend a 10° slope. If pressure points appear within 15–30 minutes, stop and re-pack (shift heavy items 2–5 cm closer to spine or move downward 1–2 inches as needed) and re-adjust belts.
Dial-in strap tensions and packing geometry
| Component | Target setting / location | Validation test | Troubleshooting |
|---|---|---|---|
| Hip belt | Snug on iliac crest; 60–80% of load; two-finger clearance | After 1 km, shoulders should feel light; no lower-back pinch | If shoulders feel heavy, re-tighten belt and move heavy items lower/closer to spine |
| Shoulder straps | Snug to stabilize only; carry 10–25% of load; no pressure on neck | Arm swing free; no hot spots after 30 minutes | Loosen if breathing restricted; tighten hip belt if shoulders bear too much |
| Load lifters | 30–45° angle; pack top pulled in 2–5 cm | Pack remains compact on climbs and descents | Too tight = forward pull on shoulders; too loose = pack leans back |
| Sternum strap | Mid-chest height; enough tension to prevent strap splay | No restriction of breathing; shoulder straps stable | Move up/down if it rubs; reduce tension if it chokes |
| Compression straps | Snug to limit lateral shift to <2 cm | Bounce test: contents do not move visibly | Retighten or re-pack if load shifts on uneven terrain |
Packing geometry rules: place the heaviest items centered beside the spine, approximately 0–5 cm above the hip belt; medium-weight items at mid-torso level; light and bulky items in the bottom compartment and external pockets. Keep liquids low and centered when possible; shift single heavy items off the spine if they create a pressure point and split weight across side pockets.
Simple metrics to confirm setup: after full adjustments, stop after 20–30 minutes of brisk walking – shoulders should be warm but not sore, hip pads should feel loaded without numbness, and no single seam or strap should rub. If any of these occur, reduce shoulder load by 5–10% (move that percent of weight lower/closer to spine) and repeat tests until stable across uphill, downhill and level sections.
