Disclaimer: This has not been tested in anyway except for a 60lbs 8 year old boy acting as a meat load. Don't know if it would break and injure you in anyway, so do at your own risk. I did this at my own risk, especially from the wife. She was not amused when I started this project since I promised her I was done with backpacks for a while once I got my MR POPUP28. She was even MORE annoyed that I smartass myself into trouble by saying, "technically I didn't buy a new pack, I'm making one".
Anyway, this all started with how everyone was talking about replacing their POPUP's belt because it was the weak point of the pack. A Kifaru replacement was popular.
First item I got was the belt because I wanted to use it on my POPUP. But it was horrible on the newer design POPUP frame. The MR lumbar padding was actually too thick and narrow. It flow smoothly with the thicker padding of the whole frame, but the Kifaru belt was wider and not as thick. Wearing it for even a few second I knew it was not going to work, felt like there was a brick between my lower back and frame.
Then....saw a used original Stryker for sale, offered a semi serious 110 to seller but he accepted....now I back myself into a corner. Got a belt and pack, I'm in too deep now (I justified to myself and no other). So now I'm on the look out for shoulder straps for cheap, found some dang it. Now I'm REALLY obsessed. You can find used belt and shoulder straps everywhere as people purchased the wrong size or bought a used frame even if the belt was wrong, as they can just replace it. The issue was the freaking lumbar pad. It was one item that almost never go on any classified because no one ever has a spare or any reason to replace one. Broke down and called Kifaru themselves asking how much if I just wanted a lumbar pad. $60+shipping. Well that is a no go because I would of just saved up for a frame if I wanted to spend that money. So was looking at what I had in my garage, was considering using the seating pad of a LWCG .5 with some straps and velcro. But took a chance on the Kifaru Insider Facebook group, threw out a 'iso' for a lumber pad thinking no one would have a spare. Wow, 3 weeks later someone message me saying they have one and will accept 35TYD! HOLY @#^*&^#$
So now all I need was the frame, probably the most important part in the system. I did some research, watched some videos, read some posts, etc. Well @4090Sharps mentioned that he used kydex to built his. And Kifaru offered aluminum version of their frame stay. Well I went down the rabbit hole of Kydex and said to myself, why not. Kydex sheets are actually not that expensive, either is aluminum flat bars.
But the issue is how am I going to join them all together? I have no talent for sewing. But @JoyRyd introduced me to the wonderful world of rivet! I never even considered this until he posted his DIY frame idea for old ALICE frame.
So I started with 2 8X12 sheets of 1/8 Kydex (fake carbon fiber printing because I'm cool that way). 2 36inch bar of aluminum from Lowes. A cheap rivet gun set from Amazon that is now my favorite tool.
I first bend and shape the aluminum stay to my back profile then drill/rivet the kydex to the bottom, then slowly applied heat to the kydex until I was able to bend it to shape with the aluminum. Then I added another aluminum bar across the top for extra structural support.
Then I dermal slots for the straps to attach onto the frame. Cut off any pointy corner and sand all edges with some sand paper.
After that, a few straps and triglides to keep the ability to adjust the shoulder straps as needed.
Finally I used some heavy duty Velcro to keep everything in place once I found the measurement for my body size.
Conclusion:
I'm extremely happy with the outcome. The whole pack came in at 6lbs 1oz. and felt very comfortable to wear. Total investment was around $250 in parts, that includes the rivet gun kit. I first want to say that I'm in no way saying that Kifaru is not worth the money. If you can afford it, I highly recommend getting something from them as they are top of the line and their company mission is very clear and honorable. This was simply a fun project for myself. Kifaru did not lose a customer because I assembled one out of used parts, because frankly I would of never purchased a new pack from them. People spend money how they see fit, $50 backpack would do the job if you are willing to tolerate it and how often you use it. I would save up $700 for a custom bow, I would never drop that money for a backpack, but I don't see anything wrong with other who do. But for me personally, Kifaru's customers are in a whole different world and mindset. Aron Snyder spend 6+ months of the year in the field so his lifestyle depends on the highest quality possible no matter the cost. The mileage he gets for his packs in a week probably equal what I would get in a decade. Aron said it himself, if you are just a weekend hunter going on a day hunt a few times a year, go get a REI pack instead because his stuff is not worth it for what you do.
Anyway, this all started with how everyone was talking about replacing their POPUP's belt because it was the weak point of the pack. A Kifaru replacement was popular.
First item I got was the belt because I wanted to use it on my POPUP. But it was horrible on the newer design POPUP frame. The MR lumbar padding was actually too thick and narrow. It flow smoothly with the thicker padding of the whole frame, but the Kifaru belt was wider and not as thick. Wearing it for even a few second I knew it was not going to work, felt like there was a brick between my lower back and frame.
Then....saw a used original Stryker for sale, offered a semi serious 110 to seller but he accepted....now I back myself into a corner. Got a belt and pack, I'm in too deep now (I justified to myself and no other). So now I'm on the look out for shoulder straps for cheap, found some dang it. Now I'm REALLY obsessed. You can find used belt and shoulder straps everywhere as people purchased the wrong size or bought a used frame even if the belt was wrong, as they can just replace it. The issue was the freaking lumbar pad. It was one item that almost never go on any classified because no one ever has a spare or any reason to replace one. Broke down and called Kifaru themselves asking how much if I just wanted a lumbar pad. $60+shipping. Well that is a no go because I would of just saved up for a frame if I wanted to spend that money. So was looking at what I had in my garage, was considering using the seating pad of a LWCG .5 with some straps and velcro. But took a chance on the Kifaru Insider Facebook group, threw out a 'iso' for a lumber pad thinking no one would have a spare. Wow, 3 weeks later someone message me saying they have one and will accept 35TYD! HOLY @#^*&^#$
So now all I need was the frame, probably the most important part in the system. I did some research, watched some videos, read some posts, etc. Well @4090Sharps mentioned that he used kydex to built his. And Kifaru offered aluminum version of their frame stay. Well I went down the rabbit hole of Kydex and said to myself, why not. Kydex sheets are actually not that expensive, either is aluminum flat bars.
But the issue is how am I going to join them all together? I have no talent for sewing. But @JoyRyd introduced me to the wonderful world of rivet! I never even considered this until he posted his DIY frame idea for old ALICE frame.
So I started with 2 8X12 sheets of 1/8 Kydex (fake carbon fiber printing because I'm cool that way). 2 36inch bar of aluminum from Lowes. A cheap rivet gun set from Amazon that is now my favorite tool.
I first bend and shape the aluminum stay to my back profile then drill/rivet the kydex to the bottom, then slowly applied heat to the kydex until I was able to bend it to shape with the aluminum. Then I added another aluminum bar across the top for extra structural support.
Then I dermal slots for the straps to attach onto the frame. Cut off any pointy corner and sand all edges with some sand paper.
After that, a few straps and triglides to keep the ability to adjust the shoulder straps as needed.
Finally I used some heavy duty Velcro to keep everything in place once I found the measurement for my body size.
Conclusion:
I'm extremely happy with the outcome. The whole pack came in at 6lbs 1oz. and felt very comfortable to wear. Total investment was around $250 in parts, that includes the rivet gun kit. I first want to say that I'm in no way saying that Kifaru is not worth the money. If you can afford it, I highly recommend getting something from them as they are top of the line and their company mission is very clear and honorable. This was simply a fun project for myself. Kifaru did not lose a customer because I assembled one out of used parts, because frankly I would of never purchased a new pack from them. People spend money how they see fit, $50 backpack would do the job if you are willing to tolerate it and how often you use it. I would save up $700 for a custom bow, I would never drop that money for a backpack, but I don't see anything wrong with other who do. But for me personally, Kifaru's customers are in a whole different world and mindset. Aron Snyder spend 6+ months of the year in the field so his lifestyle depends on the highest quality possible no matter the cost. The mileage he gets for his packs in a week probably equal what I would get in a decade. Aron said it himself, if you are just a weekend hunter going on a day hunt a few times a year, go get a REI pack instead because his stuff is not worth it for what you do.
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