50 Litre Framed Ultralight Backpack Sewing Guide

The perfect capacity backpack for your ultralight adventures and thru hikes.

Hike Light, Hike Fast (or hike light and take it easy 🙂 )

Sew your own commercial quality backpack with beginner friendly instructions.

“I can’t believe that is homemade”

A 50L 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 ~930g including the frame, which allows it to carry loads in excess of 15kg with ease. This is the same tried and tested design I occasionally sell custom made at Prickly Gorse Gear.

Features

50L+ capacity. The main compartment is approximately 45L, 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 ~930g 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 waistbelt 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.

Multiple customisation options provided. More options and detail than found anywhere else.
Detailed discussion on different frame and hip belt types to help you get the ideal pack weight and carry capacity

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)

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.

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

ItemLength/QuantityNotes
Body Fabrics1-2 metre/yard210D to 500D nylon fabrics or laminates (e.g., X-Pacâ„¢ VX21, ECOPAKâ„¢ 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 etc1-2 metre/yard70D to 210D ripstop nylon
Spacer Mesh<1 metre/yardUnderside of backpack straps and hipbelts
Pockets<1 metre/yardNon-stretch fabrics like 210D nylon or stretchy fabrics like Powernet, Venom, or Ultra Stretch/Dyneema Stretch
Foam<1 metre/yardEVA foam (50-75 kg/m³) for shoulder straps and hip belts. Use dual-density foam is pretty good for hip belts.
Frame Sheet + StayThin 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 Webbing9 metre/yardVarious widths and uses on the backpack
Grosgrain9 metres/yardAttachment loops, binding, and reinforcement
Flat Elastic1-2 metre/yardBinding stretch pockets
HardwareVarious piecesSide release buckles, ladderlocks, cordlocs
Velcro/Hook Loop Tape<1 metre/yardVarious uses
Elastic Cord6-7 metre/yardReplaceable pocket cinch cords
Zipper (Optional)<1 metre/yardFor optional hanging pocket (#3 or #5 coil zipper).