The perfect capacity backpack for your ultralight adventures and thru hikes.
Sew your own commercial quality backpack with beginner friendly instructions.
“I can’t believe that is homemade”
A 40L backpack, following the design of modern ultralight packs: a large roll-top main compartment with multiple external, easy access, generously sized pockets. This example pack weights ~880g including the frame, which allows it to carry loads in excess of 15kg with ease.
This is the same tried and tested design that I use to occasionally make custom made packs for Prickly Gorse Gear.
Features
40L+ capacity. The main compartment is approximately 35L, with 5L of side pocket volume, and variable additional storage depending on pocket options.
Built for you. The pattern scales to your torso length, and is not restricted to a maximum height like patterns found elsewhere. Build a pack custom to your body.
Ultralight backpack design. Varies with your fabric choices, but the example XPAC VX21 pack weights ~880g including the frame.
Multiple pockets which are optional if you prefer a streamlined bag.
- Main voluminous compartment
- Huge front stash pocket. Pattern includes instructions for a stretchy fabric and larger pleated non-stretch pocket.
- Stretchy shoulder strap pockets
- Bottom stretchy stash pocket
- Internal hanging pocket
Removable 4 inch wide padded hip belt. Can be removed if you want to save some weight, and replaced with a different length if your weight changes after a long hike.
Customise to your specifications. The instructions include multiple options to give you the opportunity to build your perfect pack, including options for different hardware if you can’t get hold of fancy buckles in your country.
The guide has sections on choosing from the multiple different types of frames available for backpacks, and also describes the different styles of hip belts you could make for your pack.
This is the most detailed and comprehensive ultralight backpack sewing guide currently available, and will be updated with any new information.
Printable PDF Pattern and Full Instructions
US Letter, A4 and A0 paper sizes
Every step is illustrated and described in plain verbose language for complete clarity. No confusing wall of text like you can find elsewhere.
The guide goes out of it’s way to help beginners get started with making their own gear by additionally including a free 25 page beginner sewing tips ebook.
Sew your own commercial quality backpack with beginner friendly instructions.
Not for commercial use.
(Prices may include Digital VAT if applicable in your country)
Tried and Tested Design
I’d love to see your adventures with your build!
Suggested Fabrics and Hardware (Notions)
This is to give a rough estimate for budgeting. The sewing guide provides a complete comprehensive shopping and cutting list and should be used over this.
This is to give a rough estimate for budgeting. The sewing guide provides a complete comprehensive shopping and cutting list and should be used over this.
Links to example fabrics at RipstopByTheRoll provided (USA). I earn a tiny amount of coffee money at no cost to yourself to support more free patterns. See my page on recommended myog suppliers for alternative suppliers
| Item | Length/Quantity | Notes |
|---|---|---|
| Body Fabrics | 1-2 metre/yard | 210D to 500D nylon fabrics or laminates (e.g., X-Pac™ VX21, ECOPAK™ EPX200). Stronger fabrics (e.g., 420D/500D) for bag bottoms, back panels, and shoulder straps. Use softer fabrics for side pockets (e.g., 210D Gridstop). For front pockets, choose between non-stretch fabrics like 210D nylon or stretchy fabrics like Lycra or Powernet. |
| Frame Sleeve, Inner Pockets etc | 1-2 metre/yard | 70D to 210D ripstop nylon |
| Spacer Mesh | <1 metre/yard | Underside of backpack straps and hipbelts |
| Pockets | <1 metre/yard | Non-stretch fabrics like 210D nylon or stretchy fabrics like Powernet, Venom, or Ultra Stretch/Dyneema Stretch |
| Foam | <1 metre/yard | EVA foam (50-75 kg/m³) for shoulder straps and hip belts. Use dual-density foam is pretty good for hip belts. |
| Frame Sheet + Stay | Thin plastic sheet (e.g., 4mm corrugated plastic). Stays: Aluminium tubing, fibreglass, or carbon fibre rods (6-8mm diameter). 13mm x 3mm flat bar for aluminium stays. | |
| Nylon Webbing | 9 metre/yard | Various widths and uses on the backpack |
| Grosgrain | 9 metres/yard | Attachment loops, binding, and reinforcement |
| Flat Elastic | 1-2 metre/yard | Binding stretch pockets |
| Hardware | Various pieces | Side release buckles, ladderlocks, cordlocs |
| Velcro/Hook Loop Tape | <1 metre/yard | Various uses |
| Elastic Cord | 6-7 metre/yard | Replaceable pocket cinch cords |
| Zipper (Optional) | <1 metre/yard | For optional hanging pocket (#3 or #5 coil zipper). |
