Canvas!

2025-09-06

I have started making canvas backpacks!

Ultra 400TX is horrendously expensive and will soon run out. I am not getting new stock from Challenge. Even if it is available (it's a custom fabric, and I am a small customer) the cost of shipping has become prohibitive.

Instead, for Durable Alpine FP packs, I am now using made in Australia canvas. It is not cheap, but is easy to get and long term supply is assured.

We all know how durable 20 year old Macpac's are.

The big surprise, a canvas FP pack weighs about the same as one in modern fabrics.

This canvas FP 55l Alpine pack weighs 1080g bare. The identical pack in EPX400, without pockets, weighs 1050g bare. Both are 53cm torso length packs.

I am using 12 oz canvas for the floor only. The sides of the pack are 8 oz canvas and the rolltop is 6 oz. It feels solid, but weight is very sensible.

8 and 6 oz canvas are 65% polyester 35% cotton. 12 oz canvas is 52% polyester. All are waterproofed, and can be re-waterproofed with a paint on product.

In my experience canvas is more water resistant than EPX400/200. XPac, and Ultra (while it is in stock) remain the best options for water resistance.

Everything but the pack fabric is identical to any other FP backpack.

I think, construction and feature set are the main determinants of pack weight.

I now have a overlocker, which allows me to protect the internal edges of my canvas packs in places where binding is not possible. I also only use binding for seams that are too thick for my overlocker.

I have good stock of both XPac and EPX200, ultra though, is like hens teeth.

The straps and waist belt of all my packs changed in the autumn. They are now very similar to those on a Hyperlite.

I needed to change my waist belt as the old style waist belt struggles with big loads (I never intended to make big packs, but here we are). Waist belts now feature best in class NZ made 45mm webbing, and come with 2 slots for either ice clipper's or large 1.4l removable pockets. There are 2 reinforced tabs which can be used (with cord) to form a gear loop if required.

This has allowed me to offer a small waist belt which has proven popular recently. Along with medium and large. If you twist my arm I can make a custom size. Previously this would have required a new pattern, but now it's a simple as a few snips. I don't recommend going bigger than large, the 45mm webbing is fine.

I noticed last summer, on a 14 day mission (with packraft) I could feel the 20mm daisy chain over my shoulder through the 10mm soft EVA padding, it is no longer there. Shoulder straps now have hard 5mm EVA foam padding. The top 14cm of the straps are internally reinforced. I have paid a lot of attention to durability and weight transfer/spread over the shoulder.

I have turned my 3D Spacer Mesh around, the surface that rests against the body is now a smooth weave. This is to cut out the seeds and leaves that used to accumulate on the underside of straps and waist belts, and make bio checks for DOC workers and volunteers easier.

FP now also stocks more colours HDPE gridstop. Currently black, light grey, bright blue and burnt orange, with purple and dark grey currently stuck in customs. Black HDPE gridstop is now my standard for straps and waist belts.

I am also about to receive a small shipment of Chinese XPac style laminates. Dimension Polyant XPac is only available through the NZ agent at a very high price, and in very large quantities. This is why the DP XPac I still have is available in only a few colours. I bought it 5 years ago when I started out, at huge cost. I still have stock.

This Chinese laminate is available at similar cost to EPX200, I can order smaller quantities and many colours, shipping is reasonable, the factory is really great to deal with, and quality is good. One thing I am certain of, the DWR (durable water repellant) is a lot more effective than that used on Challenge fabrics. To begin I will have a small stock of purple, orange, grey, red wine, teal and powder blue. I expect to use this for rolltops, combined with with my favourite DP XPac VX21 Cire for the main panels, until I trust the new stuff. I expect it to turn up soon, but can't be certain exactly when.

My latest pack order form

Happy tramping. David