Jerry, I've thought of that. I worry about the foam rolling in the pad tube if it's not bartacked anywhere. I've seen that happen a lot. ULA once had a run of their old style shoulder straps that weren't bartacked, and the foam just rolled around. Not good. And yet, I see plenty of MYOG packs sewn this way. The 5 Yards to SUL pack is one example. I really wonder if their foam starts rolling around...
Adhesive cloth seems like a neat idea. I'm pretty set on using Xpac for the straps though.
I just tried sewing a strap, but made it too narrow, so i'll try again later.