How to Modify an External Backpack Frame
Modifying an external frame backpack is easier than modifying an internal frame backpack because all of the hardware is on the outside. You can see the bolts and webbing that secure the fabric pack to the frame. You can also see how the frame is constructed. While all backpack models will require different specific steps for modification, some will ensure you do not cause permanent damage to your pack.
In addition to tinkering with pockets and straps, the most likely reason to modify an external frame backpack is to accommodate heavy, bulky loads like an animal, lots of climbing rope and heavy camping equipment.
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Things You'll Need
- Camera
- Ruler
- Nylon flat webbing
- Bolts, screws and washers (varies with pack design)
- Buckles, slides and D-rings (varies with modification)
- Pack cloth
- Sewing machine
- Heavy gauge sewing machine needles
- Nylon thread
- Hollow aluminum tubing (plumbing supply)
- Tubing cutter (several types of saws will do)
Instructions
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Modify Fabric Pack Components
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1
Remove the fabric pack from the external frame. Note each step you take to ensure proper reassembly.
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2
Draw a line on the pack to sight the location of additional pockets and straps. Measure the dimensions that you will eventually sew. Add width dimensions according to the item you hope to store in the pocket. Add two inches to every dimension to account for a hem and stitching borders.
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3
For pockets, cut pieces of pack cloth to the appropriate dimensions. Reinforce the edges of the pockets by sewing a hem on each piece. Sew the pocket onto the pack; match up the hem seam and the line you drew on the pack. Remember to sew back over the ends of your sewing lines to add strength to the pocket.
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4
For additional webbing straps, sew onto existing webbing. You want to minimize stitching straps into structural fabric; there will be so much force exerted on such a small piece of fabric that it is likely to rip.
Modify Metal Structural Components
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5
Remove the fabric pack from the external frame. Note each step you take to ensure proper reassembly.
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6
Look at the joints on the frame. Are there rivets, locking rings, bolts and screws, or bolted webbing? Record the materials, their dimensions and their placement. Take pictures of the original structure.
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7
Purchase aluminum tubing that will couple with the existing metal frame. Purchase additional hardware to match that already on your pack.
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8
Purchase four elbow joints that can be tightly inserted into the existing frame. Insert two elbows at the bottom of the vertical tubes on your external frame.
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9
Cut two lengths of aluminum tubing to the desired depth of the rack. Cut a third length that matches the width of the vertical tubes on your external frame. Insert remaining elbows into joints.
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10
Thread additional webbing from the rack to the top crossbar of the external frame. Now your load can rest on the rack, as well as be secured with webbing.
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1
Tips & Warnings
Look for manufactured packs that mimic your desired modifications. Scrutinize the assembly of other packs before you commence with your own modifications.
Since you will require such short quantities of aluminum tubing, ask your plumber to save scraps for you.
Webbing is cheap. Use lots of it to support any modifications. There are many brilliant uses for webbing in the back country--it is worth having extra on hand.
Any homemade gear can be dangerous in the back country. If your pack falls apart because you tinkered with it too much, you won't have anyone but yourself to blame. Manufactured equipment is tested extensively. Test your own modifications on walks around your neighborhood first.
