Not sure the gorilla will work out over time. It seems to put the load right in middle of my lower back and back is bothering me. I think too much isolated pressure in that spot.
I'm wondering if bending the stay with less curvature will reduce this.
I have the later version of the Gorilla and it is the most comfortable pack I have ever owned. I've carried up to 27 pounds with no issues. With your issue, the only thing I can think of is that the frame size may to too long.
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pack is a medium height. I know I'm not a small but this type pack may just not work for me.
Have you tried calling and telling them what problems you are having with the fit? Maybe they can replace or tell you how to adjust things.
It's a 2012 model. I have bursitis that bothers me from time to time and the lumbar belt attachment being more narrow than I'm used to just aggravated my lower back from the pressure being in that isolated area I think.
Looks like this pack may not work for you. Rather than tinkering with the frame, I would sell and consider another pack. A lightweight pack that may work in this size range is the ULA Ohm. ULA packs have a more substantial hipbelt (I have the Circuit) plus, on the current model, the hipbelt has a verticle adjustment so you can size exactly to your torso length.
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Thanks for the input!!!