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Posted: 5/7/2026 2:03:48 PM EDT
[Last Edit: PistoleroJesse][Edited]
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I purchased a Pig 40hr pack that didn't come with a frame sheet and has no ready made one. I found some McMaster HDPE that seemed workable. Also saw this Eberlestock one that seems like it could be trimmed to fit. VISM also has some level 3A UHMWPE but I'm not sure it would be stiff enough. Any one have some better ideas or first hand experience to share? |
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Sounds cheap and probably not what you looking for. I use a plastic clipboard in a camelbak HAWG. Very rigid and keeps the bag from flopping over. |
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“If you live here and your allegiance is to another nation, you are an enemy.” - C10 - 6-7-25 - 1816hrs
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Originally Posted By Old_Rakkasans: Sounds cheap and probably not what you looking for. I use a plastic clipboard in a camelbak HAWG. Very rigid and keeps the bag from flopping over. Interesting thought. To that end, I also found this 11"x17" aluminum clip board that is pretty close to size. Also found that Down East Industries (unfortunate acronym) makes a 1621 X Frame. They makes other plastic frames for various military rucks. This looks like there are some diy trimable lengths with it to... |
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There may be 3d printable models or someone on etay or fleabay that are printing them. The one above my post for $28 doesnt seem like a bad deal. |
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Corrugated plastic works too. All those election signs you see around town? Alot of those are corrugated plastic. When election season is done, get some. That's what I did for a couple packs. Go down to your local election office and ask them if they can save you a few signs when they go to collect them all, so that you can recycle them instead of throwing them away. For added rigidity, I taped one running sideways to one running up and down. That pack has zero bowing. |
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Originally Posted By marnsdorff: Corrugated plastic works too. All those election signs you see around town? Alot of those are corrugated plastic. When election season is done, get some. That's what I did for a couple packs. Go down to your local election office and ask them if they can save you a few signs when they go to collect them all, so that you can recycle them instead of throwing them away. For added rigidity, I taped one running sideways to one running up and down. That pack has zero bowing. That's a good option that's also cheap brand new. |
| I've used HDPE sheet, corrugate plastic, and even a trimmed down cutting board. Heck, I used a piece of 1x10" pine cut to fit in a pack I had as a kid. Plenty of workable options. Don't overthink it. |
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| SKD emailed me and said they typically trim down the Army 3day replacements. |
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Originally Posted By PistoleroJesse: SKD emailed me and said they typically trim down the Army 3day replacements. $20? Seems like a no brainer. |
So I went and bought the 1621 X Frame form Down East Industries. It is indeed a bit too long. But a happy coincidence was that it fit my Kelty Redwing 30L. And the frame sheet from the Kelty was the perfect scavenge material to use for making a smaller frame sheet for the PIG. All is well that ends well.   
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Originally Posted By cap6888: @PistoleroJesse DEI makes good stuff. We would love an AAR on the X frame. Seems as it could be a good solution for frameless/frame sheet packs. Would be simple enough to cut down a bit if necessary. I'll write up something after I've used the X frame for a spell. |
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Did 5.6 miles today. Started with 30lbs of sand and two 32oz nalgenes making 34lbs. Son did 20lbs in a Go Ruck. We made out to the VFW park we ruck or run to on Memorial day, then he figured out he bit off more than he could chew. I traded him water for the 20lb ruck plate. So 50lbs in the Kelty 30L Redwing was a bit much, but only because it's load management didn't allow me to place high on back. Sand bag sunk to botom of the bag as did the weight plate in the hydration sleeve. I think the X frame is indeed an upgrade to this Kelty 30L and does fit it well, but to make full use of it in most packs that will fit it, I think careful packing will be key to loads heavier than 30lbs. |
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I've made a good many frame sheets out of 1/16" thick black HDPE sheeting from Grainger's-- obviously other vendors for same sheet plastic. This thickness of plastic is suitable for small to medium size packs and can be cut with decent compound aviation shears. Packs larger than smallish Medium-size packs should, ideally, come with some sort of OEM frame. I've never dealt with HDPE over 1/16" thick because such thicker plastic is unsuitable for a frame sheet since it is resistant to bending; a frame sheet must bend with user's body. A frame is far better for larger packs, and many of the best frames include a certain amount of "bending". I've seen some frame sheets, intended for packs of medium size, which incorporate aluminum frame stays for added rigidity. Certainly, possible for a DIY type to add such stays. Expert level but not rocket science either. Make certain to know how to bend such stays to conform to user's back. When constructing a frame sheet, it is extremely useful to select a pack which has a dedicated compartment for a frame sheet. Sometimes a water bladder compartment will do. The idea is to provide a "home" for the frame sheet into which it fits well, encapsulates the frame sheet, and thus stabilizes the entire pack. How "well" the DIY frame sheet fits--and how well it works in practice-- is up to the constructor. Search my previous comments on frame sheets on this site, as I'm not inclined to repeat my remarks for the umpteenth time. Get accustomed to hearing the word "Template" being mentioned. Some frame sheets are much easier to make than others. An example of a complex frame sheet is one for the common LBT 3-day pack. The compound curves on the typical LBT 3-day pack are quite complex and changing in radius along its length. I have never used the expensive OEM/LBT frame sheet for this specific pack, so no comments on its fit. It's probably best to buy the Optional frame sheet from same mfr as the pack--if such is offered. The LBT plastic frame sheet with glued-on closed cell foam for their 3-day packs is reasonably priced: LBT 3-Day Pack Frame Sheet Anyone adding or making a frame sheet can also make a similar pad of closed-cell foam (as from a cut-up GI sleeping mat) to go with their frame sheet. Adds some user comfort, and also adds "some" built-in floatation in water. |
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