I just came back from a nice vacation to see your new posts. Very impressive work!!
Looking forward to hearing the full test report!
When you first went down this path months ago and I talked about making a new all carbon back stay support I figured it would only take a few weeks to knock something out ... well, about 4 months now and I finally made the first prototype to test out. This first unit is WAY over kill and soo stiff that you can't flex it one little bit along the spine. The sides that wrap around the waist seem just about right for the flex and weight. I used honeycomb along the spine to be really light and stiff but used way too much carbon fiber. Current weight is about 240 grams and I think I can reduce the weight to about 160 to 180 grams pretty easy. I hope to make version two in the next few weeks if I can find some time..... Once perfected, I hope to load up about 40 lbs in the Gossamer Gear pack and see how it feels. Right now, it fits my back perfect and has about a half inch gap molded into the middle section of the back for a little air flow. I originally thought I would need wider wings at the top like you have to hold the pack out but found the single attachment point to "hang" the pack from the top center seems to work well. At least in the office carrying 15 lbs. 30 to 40 lbs. might change the way it works and feels?
I will probably add a small piece of foam padding at the top of the stay where the carbon rest at the base of the neck. Other then that, I don’t think I need any extra padding or support. ???
Would love to hear your thoughts and insight before I go for version #2.