The Hybrid Pack System - Revisiting the SAR Hybrid Pack

 

Mist on the Mountain (photo by V.A. McMillan)

Title: The Hybrid Pack

Last night I received a comment on an older post Build Your Own Backpack (https://mtnmanblog.blogspot.com/2012/06/building-your-own-backpack.html) requesting more information on the hybrid pack I designed and proto-typed. As this is project dating back to 2005 through 2008, pictures were few, but I did locate a few original drawings and notes. So, in this post we will explore the hybrid pack system, which was a blending of ideas between a cargo/gear vest and a day pack. With a light sprinkle of military design influence where specific gear is carried in purpose designed pouches or pockets.

 

The Original Hybrid Pack (circa 2005)

 

The SAR Hybrid from 2007

The top photo of the yellow hybrid proto-type was where this all started. I was looking for a soft pack that could be carried in my backpack from trailhead to basecamp and then deployed carrying all the essentials for day hiking – camera, water bottle, first aid kit, multi-tool, knife, jacket, and lunch.

 

The Hybrid in Action (July 2005)

At about this time, I was also involved with my local volunteer search and rescue (SAR) unit. While there I proto-typed a couple different gear vests and the SAR hybrid pack (called the EXOSAR, on some of the drawings.) When I left the SAR unit, I left all the vests and the SAR hybrid pack behind for other SAR members to make use of during SAR training or operations.

While I cannot direct the commenter to a location to purchase the hybrid style of pack, I will endeavour to share enough information here, for them to build their own hybrid pack and it will allow for the customization of the pockets and pouches to fit their personal gear. I will share a few more pics and then end with the design notes and build sheets.

Shall we…

 

Right Side

Left Side

Front

Back

(Click on photos for a larger view.)

 

The Original Proto-type Hybrid Pack Notes (2005)

Improvements for the Proto-type Hybrid Pack (2005)

SAR Hybrid Layout (2006)

SAR Hybrid Design Sheet (2007)

Design Sheet Hybrid vs Vest (circa 2006 or 2007)

Now just a few pictures showing the layout on fabric and the cut out base layers - inner, outer, and foam sandwiched in between. Placement lines for where the webbing will be sewn are also visible.

 

Design Chalked on Fabric

Shoulder Straps Sewn to Body

So, you may notice this pack system starts with a garment like base layer, which includes an outer and inner layer that sandwich a layer of ¼” foam. The edges are sealed by sewing seam tape over the perimeter edge. The base layer of webbing for the harness is sewn on top.

 

Some of the Cut List for the SAR Hybrid

The Cut List for the Original Hybrid Proto-type

Then all the pouches, pockets, and assorted attachments are added to the base. Each item is basically built as a stand alone item before being sewn to the base. This allows an experienced fieldcrafter to only build the gear holders necessary to carry their gear…and very little waste or unused pouches, pockets, or accessories. Obviously, you must know what gear you need on a typical trip to the field for this to be effective and efficient. The military uses PALS and MOLLE as methods to have a base layer vest or pack that can have pouches, pockets, and accessories added or removed depending on the mission. In my opinion, the hybrid pack seems to work best with hard mounted items. Thus, different field missions would require making separate hybrid packs.

Pocket Detail from SAR Vest 2008

The big bonus to the hybrid pack system is it is fast to build. The base layer can be sewn together quickly and is soft enough to be easily manipulated through the sewing machine when attaching the pouches, pockets, or accessories. In my experience, unless your sewing machine has a tall and deep throat, manoeuvring a pack through the machine becomes more and more challenging as the pack becomes more complete. The one downside to a pure gear vest, is lack of breathability. Too much of the torso is covered by fabric. The hybrid pack is very open on the front allowing excellent air circulation and humidity control.

I hope this helps explain the hybrid pack a bit better. Maybe this will inspire others to start making their own gear?!? Best success!!

Until next time…if you cannot find the gear you need, it is time to learn how-to make it yourself!!

 

Mountainman.