Thanks for all the kind replies, I don't know who was more amazed at how well it turned out, me or my wife. I was so nervous at first to start cutting up the xpac, but once I started I couldn't stop, just too much fun!
Stuart - I wish I would have thought about weighing out the pieces before I put them together, it would have been neat to see how much just the fabric weighs. But when you add in buckles , bungee cord, webbing and gross grain the inside seams the weight adds up.
John - I like your idea for therapy! I am hoping to finish up my second pack tonight and will have to get some photos and post.
Nathan - The 4mm is the thickness of the foam mesh, so my straps are around 8mm thick, I did put a piece of 330d Cordura between the foam just to make it a little stronger. I would be interested to compare thru-hikers 3d mesh to the foam mesh from Rockywoods. Has anyone compared the two??? Thru-hikers is defiantly more expensive but i wonder if it is any better?
Jared - The green xpac feels lighter then the grey, The green looks like it has a 70d ripstop for the top layer, where the grey is not ripstop, and feels heavier and stiffer, which i like for the bottom and back of the bag. I do want to try some of there red and orange xpac, I hope it is like the green.