I started working on a Pack System for an AT Thru-Hike (April Start - NOBO) a little over a year ago. I knew what I wanted but it took awhile for me to find materials that would give me something close. I first made the frame part out of Aluminum then found some flat sheet Titanium (Thru-Hiker.com) that I was able to heat and bend into the different parts of the frame. I used Aluminum Easton tubes for the up-right support at first then replaced them with Carbon Fiber tubes from Fibraplex. The stripped External Frame weights under 7oz. It is full size and very strong. I made the Pack Bag out of some left over material and it also very light.
At first I made my Hip Belt and Shoulder Straps out of Silnylon like most others are made. My goal was a to find a material that I could use that would not absorb moisture and push the pack away from any contact with my body. This I would call a Moisture Wicking System. If it worked I would have a system that would be very cool to carry and not over-load the moisture wicking garments I might need to wear. My first real prototype was a little weird looking but proved the idea would work. I happened to luck upon some mold-able plastic that is used in the medical field. I was able to get enough samples of this material to made several version. My last version is about as close as I think I will get using this material. The plastic material is soft to the touch and made to be used next to your skin.
I hope to use this system or an up-dated version for some miles on the AT this April - NOBO - starting 1 April 2005 at Springer Mt.
I just finished an 8 week Radiation and Chemo - Cancer Treatment Program and have a lot of tests and exams over the next several months. I am alive and well as you can be this close to when the treatment was over. I have managed so far to keep the month of April clear of any appointments. My plan is to try and get about 30 days on the trail going North and play it by ear from there.
I have posted 3 pictures of the Moisture Wicking System to include pictures of the pack on my Photo Gallery here. I don't know how to add a link to my Gallery.