A Vintage external frame backpack is durable and reliable – with a little TLC, they can serve you for years to come.
Gearing up for your next big hike? Before reaching for that dusty old external frame pack that’s been sitting in storage, it’s important to thoroughly inspect it to ensure it’s still in good working order.
Though vintage packs have a reputation for being bombproof, age and extended storage can take their toll.
This straightforward beginner’s guide will walk you through what to look for when evaluating the condition of an older external frame backpack.
We’ll also cover easy repairs you can make at home to refurbish an outdated but trusty pack and get it back on the trail.
From replacing broken pack fasteners to fixing torn mesh and fabric tears, we’ve got you covered on how to diagnose issues and breathe new life into your tried-and-true backpacking companion.
Inspecting an External Frame Backpack
When first examining an older external frame pack, start by looking for obvious signs of wear, tear or damage. Key areas to check include:
- The frame – Look for bent aluminum tubing, cracked welds, or broken support rods. Give the frame a gentle bend or twist while holding it horizontally to check for brittle spots.
- Fabric – Scan all fabric surfaces for rips, holes, unraveling seams, or fading/rotting material. Give special attention to high-stress areas like hip belts and shoulder straps.
- Zippers – Test all zippers and ensure they open/close smoothly without catching or binding. Examine the zipper teeth for damage or misalignment.
- Fasteners – Check all buckles, straps and clips to confirm they latch securely without slipping or failing to catch.
- Mesh – Peer closely at mesh surfaces and stretch webbing for snags, tears or complete blowouts.
If issues are found during inspection, the next step is determining what level of repair is required, or if the pack is unsalvageable.
Damage to the frame generally necessitates professional repair or replacement. For fabric, zipper and fastener issues, many fixes can be easily achieved at home.
Common External Frame Pack Repairs
Performing your own simple maintenance and repairs on an old external frame pack helps preserve its lifetime while saving cash. Below we cover several common fixes for vintage packs suffering from wear and tear:
Replacing Broken Pack Fasteners
Overextended use can lead to broken buckles, damaged strapping, and failed fasteners. Fixing these issues requires basic supplies:
Required Materials:
- Nylon strapping material
- Fastener hardware (side release buckles, ladder locks, etc)
First, remove all remnants of the broken fastening components from pack material. Then measure and cut replacement strapping to size with ample length for webbing through hardware.
Attach new fasteners to strapping using box-x stitching, bartacks or heavy-duty thread. Finally, re-secure strapping to original anchor points on the pack exterior.
| Nylon Strapping Roll | $8 |
| Fastener Hardware 5-pack | $12 |
Prices vary based on materials used and hardware types
Fixing Mesh Tears
Mesh provides ventilation and support on many vintage packs. But extended abrasion can cause unsightly tears and holes. Fixing damaged mesh only requires a few key items:
Required Materials:
- Mesh repair fabric
- Matching thread
- Curved hand-sewing needle
To complete the fix, first thoroughly clean and dry surrounding mesh area. Then determine size of patch material needed to generously cover tear. Pin the patch in place under mesh, and use a whipstitch to sew edges down, sealing the rip. Finally, test integrity by gently pulling mesh in all directions.
| Mesh Repair Swatch | $3 |
| Curved Hand-Sewing Needles (5-pack) | $5 |
Mesh color availability varies
Fixing Fabric Tears
Fabric tears on pack body seams and high-abrasion zones can worsen over time. Fixing small tears now prevents bigger headaches down the road. You’ll need a few essential mending products:
Required Materials:
- Iron-on fabric repair tape
- Patching fabric
- Matching thread
- Hand-sewing needle
First, thoroughly clean the area surrounding the tear to remove grime. For small holes, apply iron-on tape per package instructions. Allow to cool completely. For larger holes, cut a patch from fabric in a matching color.
Pin the patch over the tear, then hand-sew the edges down using a whipstitch. Test integrity by gently pulling at the mended fabric area.
| Iron-On Repair Tape | $5 |
| Fabric for Patching | $8 |
| Hand-Sewing Needles (5-pack) | $5 |
Use heavyweight nylon pack fabric
Replacing aging zippers and making significant frame repairs on vintage external frame packs often requires professional assistance.
But for tackling basic fabric and fastener fixes, you can breathe years of extra life into traditional backpacking gear with simple DIY maintenance.
Follow the tips above to keep your older pack going strong for seasons to come!
