What is the most durable sewing thread that you would recommend for pack panniers? These are constructed using 1680 ballistic cloth and really take abuse. Some of the seams have broken open during our last trip to the Winds, so I am looking for some really robust sewing thread. Brand, type of thread, and size are needed. More concerned about long term lasting ability than anything. Thank you.

Bonded nylon (B92 would probably be what you want) is the way to go, and you'll need an industrial machine. if there's no way you have access to an industrial machine, B46 will work in some home machines if they have enough tension adjustment room (it's slicker than other threads so typically requires quite a bit higher tension). The 46 is a lot stronger than anything else you could use in a home machine, but still probably not as heavy as you want. 92 is widely available, 46 is a little trickier to find. OWFINC carries both.

I do have access to an industrial sewing machine. Thank you very much for your response.

Charlie

B69
"Bonded Thread
When thread passes through a sewing machine needle the friction creates heat and may cause the thread to fray. A bonded thread has a coating that reduces friction. Bonding is helpful if you are doing high speed sewing with thread size 46 and higher."

http://www.rockywoods.com/Sewing-Thread/Bonded-Nylon-Thread-4oz-cones

If you are sewing by hand, on your trip, dental floss is very strong.