To determine shoulder girth, measure all the way around the chest, arms and back at a distance of two inches below the top of the shoulders. To avoid false readings do not take the measurement after inhaling deeply and expanding the arms.
The sizing pertains to the shoulder straps and their attachment points. The volume of the pack is the same for the M, L, and XL sizes. The XXL has about 5% more volume.
Included with the kit are all the materials needed, and detailed, step-by-step instructions with many illustrations.
Notions needed: White or light-colored non-permanent marking pencil for marking the dark webbing and fabrics. Clear adhesive tape, such as Scotch brand. Glue stick. Recommended: 1/4" brass grommet and installation tools, brush-on superglue.
We recommend our ray-way thread for sewing the backpack kit. We consider it to be the world's finest sewing thread. This thread is not included in our kits, but is a separate item listed on our order form.
Specs
Weight: 9.5 ounces
Height: 23" without extension
Volume:
Pack body: 2,100 in3
Pockets: 400 in3
Total volume without extension: 2,500 in3
Total volume with extension: 3,700 in3
The pack is intended to carry ray-way gear, and not the usual profusion of expensive, heavy and bulky paraphernalia found in commercial backpacking stores and catalogues. Therefore, pack size is moderate. The person on a long trip, fresh from resupply with a load of food, uses the pack's extension collar because this increase in bulk is only temporary.
Along with one small internal zippered pocket, the Ray-Way pack has three external mesh pockets. One is located on the right side of the pack, for my water bottle-kept there for accessibility. This pocket is made of mesh to allow the bottle's condensation to evaporate. On the other side is a pocket for the fuel bottle, also mesh to permit the fumes to evaporate. And on the rear is a large pocket for stowing the tent fly or tarp when it is wet with the morning's dew. Each of these pockets is fitted with elastic in the top hem, to help secure the contents.
When the backpack is lightly loaded, one can loosen the shoulder straps, tilting the pack backwards somewhat, and giving more ventilation to the back area. The heavier the pack is loaded towards its top, the tighter should be its shoulder straps, keeping the backpack more vertical.
Why not use a frame and hip belt?
The vast majority of highly-touted features on most packs actually work against a person. For one thing, they tend to sap a lot of time spent fiddling with them. For another, they add weight, and of course expense. Contrary to hype, most of those features are designed for marketing rather than hiking.
With a light to moderate load, a hip-belt is unnecessary. And of course we do not normally recommend hiking with a heavy load. Regardless, while carrying any kind of load, as you hike along the trail your shoulders, spine, and hips twist, or rotate, in opposition to each-other. A hip-belt resists this opposition and so interferes with natural the natural bio-mechanics of walking. Without a hip-belt, you hike more natural and free. And this translates to a more efficient style of hiking with less effort.
Two Stowbags
We recommend using a second ray-way stowbag for your spare clothing and other items inside your backpack. Load the heavy food items into the pack first, followed by the quilt in its stowbag, then the clothing stowbag. Both stowbags sit in the backpack vertically, and since they are the same diameter as the ray-way backpack, they both fit it perfectly.
Pack Straps
Our pack straps are adjustable in length with a small buckle on each side. Typically with most packs, these buckles are attached to the end of the shoulder straps, such that you pull down to shorten. With the Ray-Way pack, the buckles are located at bottom of the pack, such that you pull up to shorten. While this arrangement is unfamiliar to most hikers, it is much more effective. Namely, it moves the buckle and the webbing tail from out of your armpit area, to down on the pack where it belongs. This streamlines the pack, makes it more comfortable to carry, and prevents chafe to the inside of the upper arms.
We have designed a new closure for the ray-way backpack. It is an optional feature that goes on the upper part of the pack body, where the pack body joins the lower part of the extension collar. It weighs just a quarter of an ounce.
The main purpose of the closure is to close the pack when lightly loaded, for example when pulling into a resupply, or when using the backpack as a day-pack. However it works when the pack is carrying a medium load also, as it helps stabilize the load from moving side to side.
We are including the closure free with the Backpack Kit. Or for those who have already made a Ray-Way backpack Kit, the closure can easily be added to an existing ray-way backpack (sewing required). So we are also offering the Closure Kit separately on our order form.
In addition to the instructions, the closure kit also contains the needed materials, reinforcement patches, draw cord and mico-cordlock.
Customers who made our Backpack Kit and used a brass grommet on the top of the extension collar, would use another brass grommet on the closure. This brass grommet is not supplied with our Closure Kit because when you made the Backpack you probably bought a package of grommets and tools from your local hardware or department store. If you did not use the brass grommet on the extension collar, then you probably used our alternative method. In which case you would also use the alternative method on the closure. Both of these methods are detailed in the Backpack Kit Instructions.
Zippered pocket
A functional new an add-on to our Ray-Way Backpack Kit, we are introducing a zippered pocket for your small items that need to be handy yet secure. Comes with an optional storm flap.
The Pocket Kit can be sewn into an existing, finished Ray-Way Backpack, much like the Closure Kit, or it can be purchased along with a Backpack Kit and installed during the pack construction. Weight of the finished pocket: four-tenths of an ounce. The optional storm flap adds just under one-tenth of an ounce.
Like our Closure Kit, the Pocket Kit is a separate item and must be ordered separately.
The Zipper Pocket Kit contains zipper, the pocket fabric, the storm flap fabric, and of course our excellent instructions with illustrations.
My pack is the first thing I've sewn in my life and after 30 years of climbing and hiking I have fallen in love with this pack!! Did a three day, two night hike in the Olympics with a total weight of 20lbs and the pack rode very well, also climbed Mt Stone in Olympic Nat Park yesterday with the pack pulled in with the second cord. Wow, the pack was fantastic, it hugged my back well and I added an Ice Axe loop which I used. Absolutely the most versatile pack I've ever owned. Thanks for a fantastic product!!" - Todd N.
Alexander G (Colors: B Black F/S dark-blue-green E navy. Please note our Color Options)
Personal Project in English Class The Ray-Way Backpack Alexander Goodman 16 years old; 10th Grade Lamar High School 3 May 2007
Introduction
My project is to build my very own ultra-lightweight backpack for camping and hiking. It is a package deal that can be mailed to you if you know the man that sells them. My father went on a hiking trip with Ray Jardine, he is the man that makes and sells backpacking equipment. Ray mails you all the appropriate instructions and materials to create your own equipment. We purchased several kits from him so that we can have a lightweight backpack for each of our family members. I decided to make my own backpack instead of my dad doing it for me. This will also help our physical well being and the environment. By using a lightweight backpack you are reducing the strain on yourself. This means you only bring what you need, which reduces the trash and useless stuff buildup that most people participate in. Ray Jardine has his own philosophies on outdoor activities. He suggests using as little as possible and being a courteous camper. He promotes "stealth camping," which is when you leave an area that you have slept just the way you found it so that you preserve the environment. So not only will I be creating my own backpack by scratch practically I will also be learning about preserving the environment.
Process
My father suggested that we order a backpack kit that he had recently tested and made himself. I had already watched him go through the process of making it, so I agreed to order one and make it myself with his guidance. My father had met Ray Jardine before on a hiking trip and he was given a book that I am using to help me understand why I am making this pack. The book is called Beyond Backpacking by Ray Jardine. The book talks about all sorts or practical methods and suggestions for hikers of any sort. In his book he talks about how hikers want things to be light and the backpack companies add weight, "We hikers are trying to carve ounces from our gear, and the backpack manufacturers are adding them back in pounds." (Jardine 51). He says if you really care about backpacking then you should spend your time making your own pack instead of wasting time reading other peoples opinions in magazines and buying an overpriced heavy pack. On his website he talks about how you should envision yourself doing a good job on any project you undertake. Ray says that if someone envisions a way that they are going to take on a project they will attract those ideas while in the process of making it. Ray Jardine states in an article:
"Any type of thinking is a form of envisioning. And whatever we envision, we tend to manifest in our lives. The creative process uses our mental pictures like blueprints. If those pictures are of battling and butchering, then we are attracting that." (Jardine Why Sew?)
This information really helped me when I was doing my project. I was able to concentrate on making a good and complete pack. It made the process of constructing the backpack much easier. He promotes lightweight backpacking and the idea that we all should preserve the environment while we use it. He believes it is a privilege to be able to live on this land so we should respect it for all that it gives us. He has many ways he helps preserve our backpacking areas and other places you might hike. The idea of lightweight backpacking is that you have think about what you are going to take on your trip so that it fits in your small pack. This prevents the use of useless camping things and the consumption of luxury foods. By using a light pack you reduce the strain on not only yourself, but the environment too. In his book he talks about all of the unnecessary luxury items the majority of people bring on their trips to the outdoors. I always hated carrying the usually 4lb packs filled with heavy things. I now prefer carrying the 8oz packs that Ray Jardine has to offer. It is a significant difference when you are on long distance hikes, and this is voice of experience. Our family goes on at least one long hike in the outdoors of Texas during a year. So I have had the opportunity to use a variety of packs and the weight difference is quite noticeable. Ray also promotes the use of light tents, dried food, and carrying a water purifier. My father and I are the strongest in our family, so when we go hiking, we always carry the heavy things, like water and tents. We used to carry tents that you would buy at Wal-Mart, but now we use lightweight tarps that are first of all tiny, and super light compared to the conventional tent. These tents also leave less of a mark on the place you've slept and make use of the environment around it. We order all these things from his website, ray-way.com.
Alexander G.
My project started by ordering the backpack kit itself. I then read all the instructions so I was able to get an idea of what to expect during the construction of the pack. To create and mark the pack I needed, markers, rotary cutter, scissors, glue-stick, pins, straight-edge, weights, and a sewing machine. Then I cut out all the templates for the different parts of the pack. Then I used the templates to cut the fabric. There is only a minimum amount of fabric to make the pack, so I had to be very careful when I was cutting. Then I started working on the shoulder straps. First, I cut the fabric using the templates then the foam. Then I sewed those onto the reinforcement panel that attaches to the pack. Next, I cut out the side panels of the pack and sewed those together using the templates and markers. Once the side panels were done I sewed on the mesh that holds stuff on the outside of the pack and sewed on the buckle that connects the top of the pack to the middle of it. After that I sewed on the bottom of the pack. Then I sewed on the shoulder strap adjusters to the pack and the loop on the top of the pack for easy hanging/carrying. Then, I put on the extension collar, so that the pack may have more volume to it. Then, I put in the draw strings that are used to close the pack. Once the pack was completed I checked it to make sure everything is secure and in order. Now I have my very own lightweight backpack for my personal use.
Conclusion
It took determination and hard work to put together this pack. I feel that I have actually done something useful by making it myself. I respect the work my father does to make our backpacking adventures easier and more fun by making all of our equipment. I now understand how much time a person must put into making hikes comfortable. The amount of work and time is worth it when you are able to experience the results and benefits. Now that I have a smaller pack I have to think about all the things I put in my pack, so I only have the necessities. This means that it is easy to find things I need and my hiking trip will be almost care free, because I know what I have and what I am doing. The book has helped me understand that I must respect my environment so that others can enjoy it later. By creating my own backpack I have not only made my vacations more comfortable; I have learned important ideas and values about my surroundings.
"Many thanks for the excellent quality of materials and concise, systematic instruction included in your kits! I have already completed three of your "Connection Kits" - the backpack, tarp, and quilt (deluxe 1p w/alpine & stowbag). I was a self-described "gear-junkie." I subscribed to all the magazines (such as Ad-Packer . . . err, uh, Backpacker), read and participated in all of the online backpacking message boards and cajoled merrily and proudly with others who, similarly, thought nothing of owning 6 or more backpacks, 5 or more shelters, 4 or more sleeping bags, etc. What insanity! It was as though I was trying to BUY the outdoor experience rather than LIVE the experience I so desired. Meanwhile, in consuming more and more gear, my resources were continuously stretched so thin that I was never able to create the time to get out and actually use it! And by the time that moment approached, well, some new, "must-have" item that everyone was gawking about would come out . . . Nevertheless, I abandoned all those cannonballs (both physical and ephemeral) and quickly listed my stock-piles of gear for sale. It was just as quickly snapped up and I was able to finance my entire summer along the Pacific Crest Trail! In fact, just ONE pack sold payed for ALL of my Connection-Kits!
I wanted to pass along an excerpt of an email I set to one of my buyers when they asked about why I was not playing the game any longer: 'Its funny that you should ask about what pack design I finally chose because it is just about as opposite from the (brand of pack I was selling) as you can get! I purchased and sewed a "Ray-Way" pack from Ray Jardine's website: www.rayjardine.com. I found that with the wide shoulder straps and smart, compact design, I actually preferred to distribute the weight throughout my upper body. I also found that my gaite was easy and much more effortless without a hipbelt. I must have a lot of torso swing to my pace, because it just felt 'right.' This may sound far-fetched, but . . . My "training walk" is a pretty good 6-mile route with as many steep hills as I could include. I loaded up every potential pack with exactly the same weight, exactly the same items: 4 liters of water, 18 pounds of food and 8 pounds of clothes + gear. Each pack (here were the names of 5 different brands of packs), my homebrew Ray-Way pack, and an (another brand-name pack). Same route, same weight, just a different pack on a different day. I initially gave each pack two shots, and began to weed . . . It came down to the (brand-name pack) and the Ray-Way pack. I chose the Ray-Way pack over the (brand-name pack) for 3 main reasons:
* Comfort- Again, I preferred to distribute the weight throughout my upper body. I also found that my gaite was easy and much more effortless without a hipbelt.
* Weight- the Ray-Way pack weighs less than 10 ounces compared to the 3 lbs 10oz. of the (brand-name pack).
* Pride- I actually MADE the Ray-Way pack, I feel that I know everything about it! This sense of ownership and accomplishment quickly led to my also making my tarp, quilt and most of my clothes! I can RELY on it because I'm relying on its creator . . . myself!"
Again, thanks for the inspiration & perspiration you two!" - Darrin W.
Marking out the webbing for the straps.
Drawing the lines to show where to sew the sock straps on.
Sewing the half round onto the front and sides.
Ngaio G., age 10
"I've done a lot of camping all using a tarp and making campfires where possible.
In 2004 I did the first two chunks of the Offa's Dyke Path and the final chunk in 2005. We had cookfires with every hot meal we ate, sometimes finishing off with toasted marshmallows. The Offa's Dyke took us about 15 days.
In 2006 I walked the Coast to Coast in about 2 1/2 weeks and at the end, when we dipped our feet in the sea, the water stung where my sandals had rubbed. We always walk in sandals because they are very practical and dry quickly. I carried a mini version of the backpack I made on the journey. We started at St. Bees and finished at Robin Hoods Bay.
I have camped in the lake district more times than I can remember. The first time I went it was blowing a gale and we were under a poly tarp so you could see everything and that was amazing.
I've only ever done small things with sewing like swim bags and pencil cases but my backpack was quite different. I am really pleased with it. I had several birds nests due to the machine not being threaded properly after I'd wound the bobbin - oops!
The worst problem was with a half round I had sewn on and then sewn the backpack together and after realised it was on the wrong way around, it took ages to fix but it was worth it. I'm looking forward to doing another type of kit sometime."
Sewing the front/side seam.
Me with completed backpack! (Colors: B black F/S light blue E navy. Please see our Color Options)
Note from mike: "My daughter (who is still only aged 10) today completed her backpack. She sewed this completely by herself following your instructions and watching the DVD several times. She took about 1 week and, at a guess, maybe 30 hours. It's gone amazingly smoothly and I was only really asked to clarify things very occasionally which given her age is a great testament for the quality of the backpack kit instructions. Obviously she is very pleased with herself and her confidence in her sewing skills has grown enormously." - Mike G. J.F.
"Thanks again Ray and Jenny for the awesome products you have made available. I have read Beyond Backpacking several times and have given away several copies. I have thought about making my own quilt, tarp and pack but wanted more instruction and "hand holding". Your kits are the answer.
I really enjoyed making the backpack kit. I have seen pictures of you with the pack, read the book, so I knew about the practicality of it and the philosophy behind it. The design is wonderful, the engineering is great and the execution is superb. The kit really did go together well, and I found that everything was included and with just enough to finish the kit with very little waste. This is not so with buying yardage of fabric. And I was especially amazed about half way through when I realized where it was going.
The sewing was easy and once I got the tension of my 35 year old Bernina sewing machine adjusted everything went great. I even learned some new seams from the instructions.
All and all it was the most fun I have had sewing in a long time. I imagined it was going to be complicated and time consuming but everything was spelled out in the instructions and I finished the pack in about 8 hours. I look forward to many joyous miles here in the Sangre De Christos and beyond.
By the way, I weighed my pack on a mechanical postal scale and got 9.5 Oz! incredible."
- Geoff G.
"There are many of us out there who are really excited that you have spent the time to share the kits with us. I was really excited to find that you were offering this kit. I don't imagine there is a pack available out there that has seen more miles, that every part of the pack has a useful purpose and with light-weight and function equally balanced.
For me the instructions and illustrations for building the pack were easy to follow, nice and detailed. I didn't have any problem with putting it together.
I will use the pack for long distance thru-hikes. thank you. you guys are doing wonderful things. keep it up."
"Hi Ray and Jenny, I have just completed my backpack after making a quilt and a stowbag for the quilt plus a knife. I still have a tarp to put together. I really enjoyed making my backpack. As soon as I was done I loaded it up with all the gear that I could find and found that even with a quilt and a bunch of stuff that it weighs less than my old pack did empty! Thanks! " - Eric S.
Thanks for offering the kits Ray. You have made my wife a garage widow with all the sewing I'm doing. We just spent 4 days in the Golden Trout Wilderness in the Sierra Nevada using your gear. I think we saved a hour a day just because we didn't have to mess with hipbelts. My only complaint is the design of the bomber hat does not allow for proper coverage of my ears." - Rick R.
"Ray, Pack number one is complete and I had a great experience making it. My wife and daughter took one look at it and with raised brows immediately suggested I make one for my son for Christmas. Note that I sewed an embroidery type strip on the sock hangers, before installation, that I had purchased several years ago of exactly the right length. I did this simply because I like it.
"The instructions are excellent and the video is a valued tool for the pack construction as well as for other items I make. Thank You both for a great pack," - Fred E. J.F.
"Hi Ray, I have been scrambling, but did finish the pack yesterday morning! I think it came out very well, I am quite proud of it. For me the combination of the book and the video were superb, you did a wonderful job with the instructional materials and the plans!" - David deM. J.F.
