Zpacks Arc Haul Ultra

I have been a fan of Joe Valesko’s Zpacks for nearly twenty years – back when he was just a lad sewing all the packs himself. We have kept in touch. I have tried many of his products as they became available and generally promoted them.

I doubt there has been any single person who has ‘pushed the envelope’ of the ultralight revolution quite as much as Joe. His firm has grown like topsy, which is a credit to him and I hope doesn’t give him too much stress with the responsibility of having to care for so many people and do so much work. I trust there is still plenty of time for family and for hiking.

I have a friend whose business grew so big he eventually had to sell it as it was making his life impossible. All he really wanted was to be like Maugham’s ‘The Verger’ – to have a very modest living. If you haven’t read the story, now is the time to do so. If you don’t read, you can watch it here. I’m afraid such modest ambitions are what I have stuck with since I first read the story in the sixth grade.

For Xmas I received one of Joe’s wonderful 60 litre packs, the Arc Haul Ultra which I will be taking with us on yet another ‘moose hunting’ trip to Fiordland soon. I must be nearly the oldest active NZ moose hunter. There are not many of us anyway. I only hope I can keep at it until I obtain a prize-winning photograph of this amazing beast. The last was taken in 1951. In any case I’m sure Della and I will enjoy searching for it again in those wet primordial forests.

Front view. You can see I am happy with it. I think you also can see that the straps do not dig into my shoulders.

And that the waist belt has ample width for comfort – and in this case length for a large tummy.

Another view of the waist belt.

Rear view. You will notice a well-ventilated back pocket in case you want to dry things in it. The side pockets can carry a tent (the grey thing) or a large water bottle. There are side lashings which can be used to secure things or reduce the pack volume.

I admit I was planning/promising to have my own new DIY pack finished by now/then (I have built a prototype – picture below) but we are very busy here with many other things (sheep, farm, sheds, grandchildren etc) and also I really wanted to lay my hands on Joe’s latest pack to see for example how his ideas compare with my own.

I could also have just taken his much-loved-and-modified old Blast pack to Fiordland with the new suspension system I recently made for it. It only needs a couple of minor improvements which will only take me half an hour or so. The chest pockets and strap were not quite right. I feel disloyal to it somehow. It has served me well. I will be using it still though.

My prototype DIY backpack I mentioned above. Surprisingly it weighs the same (600 grams) as the Zpacks one but in this 12oz/yd2 canvas, so you can see I will be able to make it under 300 grams in a 4.5 oz/yd2 Robic – and for about $20. If you count a sewing machine at about $200, by the time you have made yourself a pack, tent, hammock, sleeping bag etc you are going to be well in front with DIY. And it’s fun! You should never shrink from learning a new skill. I will need a couple more prototypes before I get this pack just right. When I have it just right I will post a pattern so you can have a go yourself if you want to.

Joe has been able to do a really lot more ‘trial and error’ with packs than I have, so his new pack is a real beauty. I have loaded it with what I/we will need to carry for a hike of over a week in remote Fiordland with me carrying the hammocks, tent, most survival equipment and 2/3rds of the food. Della will have a smaller pack, as usual. I have not weighed it yet, mostly because with some time yet to go there is still some ‘putting and taking’ as is usual before a trip.

I do intend to make a new lighter version of my old Grey Flyer Tent (pocket) for example before I go. I imagine the pack is under 10 kg at present with enough food for one person for nearly a fortnight, being prepared for at least an inch of rain a day, and the possibility of temperatures down to zero (unlikely) and lots of emergency equipment (eg two satellite communicators) etc…yet there is plenty of room for more! If I took a pack rifle and my ultralight fishing kit (always!) I could travel unsupplied for a month with this pack. There will definitely be blue cod at Supper Cove on the Dusky Track.

I took it for our usual 5km afternoon walk in the local forest the last few days and I intend to do the same every night until we go, which should get me (and my new left knee) into some level of training for a pretty grueling hike – even for youngsters, which we most certainly aren’t. ’70 is the new 40′, as they say. This tough hike is how we intend to spend our fiftieth wedding anniversary! Eat your heart out!

All my older Zpacks packs (I have three) have been frameless, but the new one incorporates Joe’s (no longer new) ‘Arc’ frame but with some more recent innovations some of which I had heard about. I have seen and briefly tried two of his older ‘Arc models. My son has the original and my son-in-law has a newer one, (so I have gawked at theirs and tried them on – too big for me) but this ‘Xmas’ one which I am now taking to Fiordland has all the latest ‘bells and whistles’ – and is exactly my size!

We also own three Zpacks shelters, two ponchos, raincoats, rain pants, rain kilts, Della’s Zpacks sleeping bag (I plan to get one too some day) and heaps of other smaller things. I have posted about a lot of them. As you can see, we have been long-time Zpacks fans. A great way to shed some weight – and some cash!

Getting the right ‘fit is supremely important. I have explained this many times. Most of the packs I have owned were (at least just a little) too long for me. This new Arc Haul Ultra has an adjustable torso (at the top where it needs to be – some manufacturers try to fudge adjustment at the bottom which just won’t work). It is clever. There are approximately three inches of adjustment so I can get the pack I guess nearer to the 17-18″ where it needs to be (for me) than the usual (shortest) 19″ (?) which has been such a bane to me with so many packs.

Detail of the torso adjustment. You can just easily move the straps up or down around 3″.

I don’t know whether Joe has been paying attention to my views about hip/waist belts but this pack has the waist belt attached only at the centre back – as I do – (not the sides), so it wraps around you well and supports you – even if you are stout. This is a big improvement. The waist belt is quite wide (I suppose more than 4″) so it creates plenty of friction lower down without pressing on your anatomy, and so carries the load there supremely well with no fuss.

There is almost no weight on the shoulder straps which are maybe narrower than I would have made them, but it is no matter as the pack balances well. This is a great pack for stout (most) people who have a devil of a time getting packs to fit (I know!). I’m sure it would be just as good if you happen to be (miserably) thin

Because I can make it (just) the right length the bottom of the pack is sitting just where my lordosis starts to angle out towards my bottom, but without pulling my trousers down (which can be annoying) – so it is just right. I chose the size ‘Small’ with a torso length of 16-19″ (I am 5’7″) but I had it come with a very long waist strap as I have a very large waist courtesy of too much of Della’s fantastic cooking over the years! These disparate measurements nonetheless come together brilliantly in the pack.

I tried the pack out on Della who is only 5′ and 40 kg (100lbs). This particular pack is too big (wide especially) for her. At least the straps come off the pack too far apart to suit her (very) small stature. This is not adjustable but might be made so in a future version perhaps. Joe does make one ‘Women’s size pack (also 60 litres though – Della would not need nearly that much space).

It is unclear just what the dimensions of this pack are. I will seek more information from Joe about options in a framed pack for smaller people like Della (or children). He does offer the frameless Nero which might suit her better. I think a 40-50 litre framed pack would be all she would need if she wanted that dry back though (see below) . He used to make one called the ‘Scout’ but it no longer features on his website. He has always been very supportive of custom orders in the past though.

At the moment she is very happy with a $20 pack from Amazon she took to Everest, but it has zippers which I always feel might fail. My own DIY pack (which I will probably eventually be tailoring for her) will have no zippers or anything else which can break and not be fixed or replaced on the trail. I think this is important.

Dry Back: Most people will find this to be the most delightful feature of the pack, and the one I admit I was keenest to try out. You will know I have tried out all sorts of ‘wrinkles’ on this over the years with mixed success, but Joe does seem to have hit it right on the button with a sort of trampoline arrangement inside the ‘arc’ frame which holds the body of the pack a small distance away from your back so that there is a free movement of air.

I am notorious for having a sweaty back but the last couple of very warm afternoons at least I came home from my walk with (surprisingly) a dry back even though I was wearing my heavy duty grey cotton work shirts. It will be even drier with a more breathable lightweight hiking shirt. So, problem solved – and thanks Joe.

This is the adjustable trampoline arrangement which holds the pack off your back.

Which you can see it doing here. You can also see that I would easily fit another 10 litres in the pack.

I know most people will buy the pack for hiking, but this is definitely the pack for ultralight deer hunters. That is my old Zpacks ‘Blast’ pack in the photo after nearly 15 rough years.

I know most hunters want the ability to carry large weights in case they ‘get lucky’ and have heaps of meat to carry out. This indestructible ‘ultra’ fabric and the imaginative frame (at around 600 grams) should allow that comfortably without burdening you down when it is not loaded up. I know lots of folks who are carrying a hunting pack which weighs over 3 kg empty which is more than your whole hunting/hiking kit should weigh. With this pack and some other ultralight equipment you can travel the bush as if you were just carrying a day pack – but for days at a time. This Arc Haul Ultra is just what you need.

I think it is also the ideal pack for the backpacking traveler. It also comes in a 70 litre version at 621 grams if you need a little more space, though I suspect you should try to travel light and fit in the smallest space possible. I understand that the version I have will fit in as carry-on luggage even. With this pack plus essential camping equipment, a few clothes and some electronics you should be ready to fly off on your world trip in superb comfort.

You probably know I do a lot of DIY. Are there things I would have done differently? There always will be of course, but one thing I want to do with a pack is have something which has no elements which are ever likely to fail on the trail or which can’t be fixed/replaced on the trail. My own DIY backpack will be frameless which will save about half the weight of this pack in the same (3.5 oz/yd2) fabric – or about half a day’s food. I will keep working on the sweaty back problem. Perhaps I can solve it in a frameless pack.

I believe a frame is also something which can break – as can buckles. I’m sure you would have to be very rough to break the frame, but I have seen how some helicopter, boat and bus operators throw these things around and pile them on top of each other. I would perhaps rather be safe than sorry (in my DIY design desiderata anyway).

However, it looks to me as if all the carbon fibre frame members are very solidly constructed and anyway easily replaced by the owner if you happened to break them. Zpacks don’t seem to have them as replacement items on their web page, but I’m sure if you did manage to break one (you might have to try hard) they would come to the party with replacements. They have always provided me with excellent service.

I know Joe has always sourced buckles from superior suppliers. I have never managed to break any of his buckles. They are not the cheapest you can get from Aliexpress, that’s sure. I actually don’t know how he finds some of them. For example, I had been searching (for my own use) for dual adjust 1/2″ belt buckles but the only ones on the net are the ones Joe sells! I finally decided (for the application) on webbing ‘ladder’ adjusters instead for the reason below.

Nevertheless buckles can break. If I could I would always use dual adjust buckles so that only the webbing is sewn to the pack – so that if they break they can easily be replaced – and you can carry a couple of spares. I will make my own pack with as few different buckles as I can (two?) so that you only need to carry those couple of spares against a possible disaster.

I will probably not use 1/2″ buckles either (as Joe does here. My arthritic (or likewise very cold, gloved) fingers find them just too hard to open/close them. 3/4″ is just about the minimum my fingers ‘enjoy’ at my age. I realise there would be a (very) small difference in weight, but sometimes convenience trumps weight.

Where possible I will use webbing ‘ladder’ adjusters rather than buckles too. They are easier to operate, but not to open. Some places eg your waist belt you just have to have a buckle. Dual adjust here is best as they can be replaced if you (eg) stand on them or close them in the car door and break them.

The pack is pretty waterproof with taped seams and a roll-top closure. If you add a waterproof pack liner bag it should float you across rivers and the like safely.

We always put other important gear such as sleeping bags, clothes, communications equipment etc) in an additional waterproof bag (= 3 waterproof layers). I would rather be the ultra-dry hiker at the end of the day than just the ultralight hiker.

Like many packs the back pocket is made from a very durable stretchy stuff as a wet area and for clothes drying etc. You can see I have a long length of rope in there for getting us across flooded rivers etc.

I have eliminated this stretchy stuff from my DIY packs as I don’t like getting it snagged on blackberries (as has happened with a couple of other brands of pack). Della even replaced it on my old Zpacks Blast pack with a uniform Dyneema which is what it was made from. The old pack was 4.8 oz/yd2 of this dyneema fabric and has held up for nearly two decades and thousands of miles – as well as much rougher treatment (terrain-wise) than the average hiker is going to subject it to.

The new Robic and Ultra fabrics are supposed to be even sturdier whilst even lighter than Dyneema. I am going to make my own (probably next) pack out of Robic (which is substantially cheaper than Ultra – one quarter the price). One of the reasons I make my own is that I have never had money to just throw around. Also you get exactly what you want – even of it turns out to be a disaster!

Joe used to have a ‘Custom’ button on his site (which I can no longer find) Probably if you contact him it might be possible to arrange alterations to the standard specifications. If I happen to tear this stretchy stuff on mine over time I have the ability to unpick it and replace it with a matching piece of Ultra fabric myself.

I think I am going to thoroughly enjoy this new pack. All in all though, I don’t think anyone makes a better pack than this.

Well done Joe.

PS: Since I wrote this post the pack has been to Fiordland (Dusky Track, Kepler etc), to the Everest Base Camp Trek, the Overland Track, to Mt Feathertop (& etc) and up the bush hunting/hiking with me lots of times.

It is certainly my ‘go anywhere’ pack now. I have not progressed my own pack design since I have had it as I doubt I can better it.

Some older Zpacks related posts:

Astonishing Hiking equipment by Zpacks

Zpacks Hexamid Solo Plus Tent

Zpacks Ultralight Tent

New Zpacks Sleeping Bag

Zpacks Plex Solo Tent

A Blast of a Pack

Rain Kilt

Ultralight Rain Jacket

Hip Belts

Hammock Camping – Double Bunking