I've been thinking about making a few Duluth packs. While scouting out the local budget fabric place, I found almost no Cordura, and what I did find was pretty light weight. I did find a heavier spool of canvas at $7.50/linear yard, but it was a color I didn't like. Their other canvas seemed pretty light.

However, they had a spool called Keprotec at $10/linear yard. It seems similar to Cordura, and is 88% Polyamide / 12% Kevlar Aramid.

Googling, I find it primarily used by motorcyclists in fall protection clothing since it's extremely abrasion resistant, but a British company called Crux UK used to use it in their backpacks.

So, any thoughts?

Here's what I'm thinking for a pattern. This is incomplete - I don't have anything for a trumpline or a waist belt.

Total rookie sewer, but Keprotec is like a nylon right? It didn't feel too stretchy for a pack?

Looks good - pattern and fabric - check out using a heavy duty thread - or what is called "outdoor" thread (Nylon or Poly) If you have a "homestyle" machine and not industrial - use the heavy thread both in top and bobbin - large needle - and tighten the machine UPPER tension. The bottom will be fine as is if if was set correctly to start with.

I have altered, repaired and changed many Kondos and other Cordura packs to fit a specific need. Not hard Just take your time and "measure twice - cut once". The back - strap attachemtn might be the most trick to get it sturdy enough.

I would also think about putting a map pocket on the front and handle loops on the sides. If you use a 3" long piece of 1" webbing across the top of the side seams - at a right angle - they will be more secure. Check your store-bought packs and see what you can add or improvise.

Oh, and if you are in the Mpls Metro - I would be very willing to get together and work on your project - after my Memorial weekend trip. I have 2 weeks to get the curtains done for the van, then until July to make 2 lazy slug hammock covers and one under quilt.

Thanks for the information! I am still finalizing the pattern, and still have to work a few things out - like the attachment (and where) for the tumplines, what seam to use (flat felled?), etc. Plus what to sew when.

And I'm working on personalizing it for my own use as well. I think a shoulder strap pocket or a few would be a good idea (for sunglasses, a compass, etc). I'm also thinking of making a detachable thwart bag that will clip to the portage pack. And a sleeve inside the pack by my back for a folding sleeping pad (which will serve as padding).

By "Duluth Pack", you mean "canoe pack", right? I know the name sometimes gets used generically.

I can't speak to its use in packs, but keprotec is some bomber stuff. I had a pair of LL bean boots made out of it which looked brand new the day I tossed them in the trash (stupid glued on soles which couldn't be replaced/refurbished).

if you pull this off, your 6th gen grandkids will still be using your pack!

Yes, by "Duluth pack", I mean a regular portage pack, no frame, simple design.

Think I'll do shoulder straps similar to this pattern, but I'll add a sternum strap.

http://diygearsupply.com/diy-guides/backpack/