Subscribe Contribute Advertise Facebook Twitter Instagram Forums Newsletter
610 Pack Replica
Display Avatars Sort By:
Jon Holthaus
(t25hatch) - M
610 Pack Replica on 09/27/2012 09:42:58 MDT Print View

Finally decided to do it, my first make your own pack. After quite a bit of searching, deciding, made up mind, changing mind etc., I came across Dave C’s 610 pack, and decided to closely replicate it (with a tip of a cap to him).
I find that pockets on packs are like stuff sacks, the more you have the more “stuff” you carry. Stripped down including 1.5” nylon hipbelt, sternum strap, frame sheet it’s 21.7oz. With the removable pocket (1.82 oz) it’s a total of 23.52oz. I still have to cut a few straps here and there, so my target is 23.5oz. which I’m happy with.
For my first pack I’m pretty happy with it, shoulder straps were the most difficult to find the right angles and attachment points with both at rest and when in use with the load lifters (although they aren’t really necessary).
The removable pocket attachment was very similar to Chris Piechel’s DX40 pack, which allows for a clean finish with things not hanging everywhere, which I like. I prefer to stay off trail as much as possible so this is a nice feature. I haven't tested the volume exact but guessing around 30L. Let me know if there are any questions, thanks for looking.
photo 1 photo 3 photo 2 photo 4 Pack (2) Pack (1)

Christopher Zimmer
(czimmer) - F

Locale: Ohio
Nice Pack! on 09/27/2012 10:30:26 MDT Print View

Hey Jon, nice job on the pack it looks great! Is that VX21 for the main body? Congrats on your first pack build, job well done!

Terry Trimble
(socal-nomad) - F

Locale: North San Diego county
610 Pack Replica on 09/27/2012 10:45:31 MDT Print View

Nice pack!! To me just looking at it it about 36 liters and can carry about 45 liters with roll top fully packed. You did a great job on your Xpac pack I like the modular designed type pack should last you awhile.

Jon Holthaus
(t25hatch) - M
Re: 610 Pack Replica on 09/27/2012 11:25:30 MDT Print View

Thanks for the kind words! It was a lot of fun, and see a few more packs in the near future.
@Chris - Main Pack is VX21 from Rockywoods. I modeled the straps off your design with a bit of variation. I held it close to 3" width with grosgrain, however the jaw depth (if that's what it's called?) of my pressure foot is 5/16" and I picked up some 3/8" foam with 4mm mesh (what you see in the photo), and unfortunately it doesn't fit. I do have access to an old Pfaff machine with 3/8" jaw which will help make short work if sewing the webbing for sternum strap/loadlifters. I'm using the singer 4423 Heavy Duty which is a nice machine but lacks that varying depth.

@Terry - Thank you as well, the pack is approx. 30.5" tall along back, 8.5" deep and 6.6" front, with the curved front. I do have access at work to measure volume with shipping peanuts and a box. I'll have to give that a go. I like how stupidly simple the design is, a fun one to make. Learning order of operations for sewing the back panel (when there's a pocket for frame sheet) was a learning curve to hide seams. It's safe to say my seam ripper and I became good friends.


Locale: Northwest Mass
Nice on 09/27/2012 11:32:49 MDT Print View

Great job on your first pack...I made 4 before I was happy enough to keep it!

Could you explain how exactly the removable pocket attaches?


Jon Holthaus
(t25hatch) - M
Pocket Attachment on 09/27/2012 12:12:49 MDT Print View


It's a bit difficult to explain in words, I'll attach a photo that hopefully makes sense, I just keep my webbing strap 16" long then trimmed after I knew how long wanted to run through the different hardware. The green line is the strap, and you can follow it through the (2) ladderlocs and (1) triglide. Let me know if this doesn't make sense. I like the finished clean look.


Edited by t25hatch on 09/27/2012 12:15:39 MDT.

Clint Wayman

Locale: East Tennessee, US
610 replica on 09/27/2012 13:11:36 MDT Print View

Hey Jon,
1st, that's a really slick pack-- especially for a first go! I really appreciate the clean lines and minimal design. Also, and you may have addressed this in an earlier post, but I wasn't sure: are your shoulder straps simply 2 layers of 3D mesh, or did you find a thinner foam to sandwich between? in that same vein, have you done any load testing in regards to comfort, weight distribution/balance, et al?

Again, fantastic work.


David Chenault
(DaveC) - BPL Staff - F

Locale: Crown of the Continent
re: 610 replica on 09/27/2012 13:23:43 MDT Print View

Great pack Jon, happy to help out a fellow Buckeye (I grew up in Oxford).

Daryl and Daryl
(lyrad1) - MLife

Locale: Pacific Northwest, USA, Earth
Re: 610 Pack Replica on 09/27/2012 13:33:48 MDT Print View


I have the same question as Clint but regarding the waist belt instead of the shoulder straps.

What mesh and edging did you use on the belt?


Jon Holthaus
(t25hatch) - M
Re: on 09/27/2012 14:11:05 MDT Print View

@clint - thank you for the compliment. It was a great first project, it challenges your patience. The shoulder straps are (2) layers do mesh with binding edges and xpac inner. I have provisions for 3/8" thick padded straps that Chris Zimmerman shows on his site, I just need a machine with 3/8" pressure foot jaw (I have access to one, justhaventgotten there yet.

@Dave - thanks again for your help, as well as ideas. Also didn't know you were a Buckeye (or Redhawk being Oxford). Why on earth would you leave Ohio for Montana if you like the outdoors? :)

@Daryl - right now single nylon hit belt, with provisions for padded hip belt/pocket combo idea.

I typically carry up to 3 liters of water pending some dry spots where I hike. My pack with food and water is ~21 lbs and it carries just fine. It's funny I've never had a perfect torso fit, just manufacturers fit, makes carrying a pack just more efficient when fitted properly. For me it feels plenty comfortable, but I've only put ~7 mikes on it testing it out.

Mike D.
(mpd1690) - F
Re: Re: on 09/28/2012 06:55:46 MDT Print View

Great work Jon! I'm sure it will work well for you.

Where did you buy the straps? I have been looking for a good source for colored webbing. Is it from strapworks? What thickness are they?

Jon Holthaus
(t25hatch) - M
Re: Straps on 09/28/2012 07:33:15 MDT Print View

Hi Michael,

Thank you, I got 30' (they are in feet) shipped to door for $13.76, it's a little more expensive than just black, but to give it some color I thought it was worth it. They have many colors to choose from, my packraft is yellow, and I plan to use it also to carry the raft, paddles, PFD, pull over and rain coat. I figured mine as well match it right? Ordered yellow 3/4" thick.

Edited by t25hatch on 09/28/2012 07:34:07 MDT.

Rob Daly
(rdaly) - F - M

Locale: Midwest
NICE Jon on 09/28/2012 07:42:22 MDT Print View

I love the minimalist design. The colors are cool too.

Mike D.
(mpd1690) - F
Re: Re: Straps on 09/28/2012 12:07:04 MDT Print View

Thank you.

But as far as thickness I am more interested in thickness (.04", .05", ect.) as opposed to width.

Jon Holthaus
(t25hatch) - M
Thickness on 09/28/2012 15:10:05 MDT Print View

Hi Michael,
At time of photo it was poly webbing, but it's now nylon 0.070" thick from strap works.


Locale: Northwest Mass
Re: Pocket Attachment on 09/28/2012 18:52:04 MDT Print View

thanks for the response.

so the idea is you can still adjust the side compression while the pocket is on? thats slick.

Edit: so what is the triglide there for?

Edited by adie.mitchell on 09/29/2012 15:41:25 MDT.

steve m
(smulvaney) - F

Locale: pdx
nice work on 10/01/2012 00:44:20 MDT Print View

Great job on the pack!
Can somebody comment on using a drawstring closure with the vx-21? I put vx21 side pockets on one of my packs with adjustable shock-corded closures, the material doesn't 'gather' well due to stiffness. Is this an issue at all with the top of a pack like yours?

David Chenault
(DaveC) - BPL Staff - F

Locale: Crown of the Continent
vx-21 and drawcords on 10/01/2012 10:00:40 MDT Print View

You'll want to make the sleeve for the drawcord out of sil or something comparable. I presume that's the black fabric visible.

Jon Holthaus
(t25hatch) - M
Re: Drawcord Closure on 10/01/2012 13:30:32 MDT Print View

That is correct, 1.9oz. sil was what I used.