Custom Dyneema™ Packs

40L Curve – Full Suspension Custom Pack

(7 customer reviews)


40L Curve Full Suspension Custom Pack



Please use our measurements and sizing charts when building a pack. Just because your current pack is a small doesn’t mean our pack in a small will fit the same. See the bottom of this page for all sizing information.


  • 40L body plus an additional 15+ liters of external pockets totaling 55L of pack space
  • Designed to comfortably carry around 35 LBS
  • Two removable curved aluminum support stays (3+ Oz.)
  • Fully padded non-removable back panel constructed of 1/4″ close cell foam
  • Fully padded 4″ wide hip belt constructed of spacer mesh and close cell foam (sizing info can be found below)
  • 3″ wide S-shaped shoulder straps constructed of  spacer mesh and close cell foam
  • Standard shoulder straps are designed for a chest size less than 42″
  • Long shoulder straps are designed for a chest size greater than 42″
  • Fits a bear canister inside
  • 5 point side compression with lineloc 3 adjusters
  • 4 trekking pole loops (includes 4 each of 12″ shock cords with mini cord locks)
  • Top buckle roll top closure with 2 KAMsnaps
  • ***Top Y Strap*** (now included)
  • ***Lower V Loop*** (now included)
  • Adjustable flat bottom side pockets with drain hole. Each pocket fits 2 1L smartwater bottles securely. Pockets adjust with shock cord and mini cord locks.
  • Dual adjust sternum strap
  • All internal seams sealed with Dyneema® seam tape

*Load lifters NOT available. The height of the 40L Curve Full Suspension Pack does not allow for this customization.

Weights & Measurements

  • 25/32 Oz. | 708/907 Grams (weight will vary due to torso size and hip belt size)
  • Bottom circumference: 34″
  • Top circumference: 38″
  • Pack height when fully unrolled: 34″
  • Back of pack: 11″


  • ULTRA 200 Black and White (we recommended this material for a thru-hiking) Stronger than Dyneema, completely seam taped, and still the same weights.
  • Dyneema Pack – Body 2.92 Oz with a 5.0 Oz bottom
  • Shoulder straps and hip belt 210D Gridstop
  • 4 way stretch Lycra mesh
  • Spandex/Nylon mesh
  • 3D Spacer mesh
  • Close cell foa,

Hip belt pockets can be found here 

Fanny packs can be found here


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Torso Sizing Reviews Gallery

7 reviews for 40L Curve – Full Suspension Custom Pack

Based on 7 reviews
5 star
4 star
3 star
2 star
1 star
Showing 7 of 7 reviews (5 star). See all 7 reviews
  1. Chris Payne (verified owner)

    I got the 40L Curve Full Suspension pack mostly because I live and hike a lot in the Sierra’s and must always carry a bear canister. The wait to get the pack was long, but I do have to say they are very transparent about the wait time, and my pack was a week early. I got the pack a few days before a 6 day Cottonwood/Whitney/Cottonwood trip. This pack is 15 ounces lighter than my other well know cottage industry pack of the same size.
    What attracted me to this pack was the wide straps. The pack is very comfortable with weight in it, and the bear canister fit well. I really like the wide straps and belt. Why do not more pack manufactures use wide straps like this. I had a bear can (Bearikade Weekender) with 6 days of food for two people on my first outing with this pack. The pack rides so well I did not have any fatigue. Plus I really like when people ask if your day hiking because the pack is so compact.
    Things went south on my second trip. We did the High Sierra trail in 8 day, a mellow pace. The second day of the trip I went to snug the side strap and the eyelet pulled out and tore the Dyneema a bit. I know what your thinking how can I give 5 starts and a seam pulled out. My Grandmother was a seamstress for 30 plus year, and sometimes her seams pulled, it happens. I put a little duck tape on the pack and completed the trail.
    What happened next was the reason I’m giving a 5 star rating. I e-mailed Chris with photo’s and let him know what happened. He asked me to send in the pack, which I did. I receive the pack back within the same week of them receiving it on Tuesday. I did not expect that fast of a turn around time on a repair, I am fully impressed.
    Will you have to wait to get the pack – yes.
    Will you be impressed with the quality of the pack and material when you get it – yes.
    Will you get great customer service, where the owner answers the phone -yes.

  2. tacmaster114 (verified owner)

    Ok, I get it and I’m somewhat guilty. This pack is super cool. The “cool” factor is off the charts. The burning desire to start my own YouTube channel about hiking gear automatically hits when I put this pack on. (Not really, that would be boring as hell). Beyond the “cool” factor is the comfort. This is absolutely the most comfortable pack I have ever put on. The hip belt having two strap on each side, allowing 4 ways for micro adjustments is game changing. As my day progresses and I fatigue In different areas, being able to adjust how the pack rides on my hips is awesome. The shoulder straps are beyond comfortable and the way they are cut fits perfectly. I am impressed with how the two aluminum stays transfer the weight to my hips. It carries weight as well as a full frame pack. I know it’s a spendy piece of gear and the waiting period sucks but if you are willing to shell out the money and wait a bit, this pack is worth every penny.

  3. Razor (verified owner)

    Received my New 40L Full Suspension Pack yesterday. Chris ships quickly…which was a problem, good problem, lol, but a problem. I was on the other coast of Florida when I checked tracking info and found out my new pack was sitting on my front porch. OMG…I packed up and drove across the state like a crazy person so it wasn’t sitting out there all night. Yep, made it, lol.
    The Pack is nothing short of amazing. Chris is both fastidious and meticulous with his sewing, the stitching is absolutely perfect. I called him prior to purchasing and went over a few sizing questions, took his advice and I have to say, of all the packs I own, the torso sizing based on his recommendations is exactly right for me, hip belt rides where I like it to. The best way to describe this pack would be a hybrid of an Arc Haul and a 2400 HMG. I took it out for a quick 5 miles on flat ground this morning (it’s Florida, the entire state is flat, lol), it rides great. It’s around 5” taller then my 2400 HMG, but it’s not as deep, it loads like my Arc Haul. You aren’t going to be jamming things along the sides of the interior like you do with an HMG. The additional height of this pack lets you pack cold weather layers and rain gear easily. You can really dial in your load with his pack. You can stack stuff sacks in a tight order and get the weight exactly where you want it, and it doesn’t move around. The shoulder straps sort of remind me of ULA’s S Curve, but these wrap around your chest and torso in a very unique and comfortable way, they are the best feature of the pack. One thing I loved about my Arc Haul was the twin hip belt straps, the 40L Full Suspension has them, being able to tighten the top and bottom of your hip belt independently is great, I love the weight on my hips and this pack carried 20 lbs great and the weight stayed right on my hips. With just a tech top on I still had 3” of adjustment remaining on both shoulder straps, I’ll have plenty of adjustment when I have to wear a heavier layer for colder temps. I had Chris build mine with the Pa’lante Style Bottom Pocket, I jammed a Meal 2 Go and a ziplock of skittles in it and even when I broke out in a run everything stayed put. If I had a complaint about this pack it would be the buckle on the sternum strap. I’m assuming it will loosen up a bit in time, but it’s a pain to adjust, lol. If you’re dropping a layer and want to tighten it, you’re going to be a couple of minutes feeding it through the buckle. The pack rides close to your body, on a run it stayed right with me without rolling around. Overall, the quality and construction of this pack is the best I have ever owned, time will tell how it holds up, thinking it’s going to take hard use and keep on going.

  4. Alexey Shmatkovskiy (verified owner)

    Absolutely love this pack. I have done 84km two days trip with this pack with a lot of bushwalking and offroad. Packs seat very well, center of gravity for my opinion is similar to running vest packs that I have a lot. Hip belt is very comfortable and adjustable, thanks to double adjustment on it. I am not a big fun of hip belt pocket and option of removable pockets is a great thing. Shoulder strap is wide, well supported and S-curved design is amazing far better against straight straps. I feel that packs frame system make a great job to transfer load to the hipbelt, I have loaded pack with 12kg with fully comfort.
    Based on this experience I am considering to order 30 or 35 Curve Packs for my ultralight trips.

  5. Eliot Milbourn (verified owner)

    This company is special, and this pack is special too! Chris is the owner and you can actually pick up the phone and speak to him. He’s such a nice guy and even agreed to custom size my pack between small and medium torso lengths – now who else in this business would do that!?

    I’ve put 1000 miles on my Hyperlite Mountain Gear 2400 but this one rides better with more comfort. Straps and buckles are lighter compared to some but don’t feel fragile. I’ve tried the latest Pa’lante V2 but this one’s S-curved straps are in another league, and it doesn’t barrel and fall backwards under load. I flirted with a Superior Wilderness Designs DCF Long Haul 40 but the build quality on this has it beat hands down.

    It has many innovative features including: easy lash loops on the back for your 1/8” ccf pad; functionally sized shoulder strap pockets that can actually hold a water bottle; a game-changing all-day snack (and lunch) storing bottom pocket; ‘actually reachable’ side pockets; infinitely stretchable front pocket that covers the whole height of pack; ridged strap webbing that never slips; seam sealed DCF construction (which means it’s essentially if not actually waterproof); real suspension system with dual adjust hip belt; and… I could go on… oh, and it really is LiteAF! 🙂

  6. Steve M (The Coastie Hiker) (verified owner)

    This pack is incredible. Well worth the wait on the lead time too. By the way, if you need help along the way, email them!! They’re more than happy to make sure your pack is exactly what you need. Definitely a customer for life.

  7. Mike H (verified owner)

    Wow.. Just wow. The difference in comfort of this LiteAF pack versus all my other Zpacks is night and day. This pack is AMAZING! Chris and his team (I hope he has a team for all these orders) do such a great job with the construction of this pack. I cannot wait to start putting some miles on it and really enjoy it!

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Choosing the Right Pack:

Torso Sizing:

Hip Belt Size

Below you will find a list of sizing for our hip belts. The first measurement (the absolute minimum) is the total length of foam and clip. The second measurement is the maximum the straps will extend to. Using a measuring device, pull it around your back at the level of your iliac crest and connect it in front of you. This will be your hip belt size. Using this pack for a thru-hike? Please take weight loss into consideration when selecting your hip belt size.

Small Hip Belt - 25" of foam and a total of 38" of adjustability.

Medium Hip Belt - 28" of foam and a total of 44" of adjustability

Large Hip Belt - 33" of foam and a total of 48 " of adjustability

X Large Hip Belt - 40" of foam and a total of 55" of adjustability

Torso Size Info

All packs are built to your specific torso. To find your torso length you will need to find your C7 vertebrae and your iliac crest/hip shelf and measure the distance between them. Still need help finding your torso? Check out this video

Packs without a hip belt will measure from the bottom of the pack to where the shoulder straps are sewn in. This is the same for packs with a 1″ removable hip belt or fanny pack.

Packs with a padded hip belt will measure from the center of the hip belt to where the straps are sewn in. If you choose to have load lifters then your pack will measure from center of hip belt to the load lifters.