I haul between 30-60 pounds of camera gear all over different types of terrain. The hikes can be 3-10 miles depending on location. I am using a lowepro bag now, internal frame and it just doesn’t work. Doesn’t fit right and cannot handle the weight. I know what I want and that is why I decide to make it myself. I just finished machining all the parts now just waiting for the tubes to arrive to assemble then build the harness system. A design that I think will put the weight on the hips and keep the stress from the neck under heavy load.
My goal is to get the frame in 3 or less pounds that can take the weight with ease and have the comfort of an internal frame pack. I am searching for material for the back plate to be able to hook and strap the bags on with. Any suggestions? I need a lightweight plastic that is super strong that can be milled as well and wont crack under stress.
I was thinking of using Polyethylene Sheets - HDPE in 1/8".
I am also looking for a bag reinforcement to put along the walls of the bag so the camera wont rip through it. Any ideas on that material? I was thinking of PVC foam sheets that you can bend then adding ¼” closed cell foam in front of it to add protection to the camera, lenses, etc… inside the bag.