I have started work on getting the Leprechaun pack into production. Any comments on the design would be appreciated, either here in public, or you can email me at ImlayCanyonGear at gmail. Tom
My thoughts for what its worth: I like the zipper but a reverse zipper so the coils are on the inside, coupled with protective flaps, could help with zipper abrasion protection. The lower panels on the sides and the bottom are where I've experienced the most wear. especially since the seems get destroyed and unstitch. I would suggest these panels be extended up higher on the pack, and have the thread less exposed. One step further would be to make them out of vinyl-coated poly/nylon to offer better abrasion resistance and easier patching. The seams in my pack abraded away--so did much of the lower panels. When I fixed my pack I also modified it replacing the cordura panels with two layers of vinyl-coated polyester panels, hidden seams, and extend the panels joints to higher upon on the pack. I just punched a few drain holes in the bottom to match the holes in the foam. This is trivial but an external helmet attachment would be handy. Because the pack is supposed to be small, I often use the side compression straps to carry my harness, kneepads, and helmet externally for the approaches and exits--if they don't warrant the use of these items. I use both straps to attach the helmet so it won't move around. This works fine but is a small nuisance since it does mean I have to disconnect everything in the compression straps to get to the helmet. If you could find a way to add a designated helmet attachment that could be a handy feature.
I have a revised zipper method that addresses this problem, including using a reversed zipper as TCarlisle suggests, and other changes.
I have seen many well-used Leprechaun packs, and have not seen many that are torn up in those sections. Maybe that is because the zipper fails first. Do other people find their Leps beat up here? Pictures would be helpful.
Perhaps your name should be added to a few others. Those famed for their ability to carry large amount of gear on their Lep pack. Eric Godfrey, Jenny West and some others. No gear flopping around is mandatory...or your "friends" might keep yanking on it or make it appear to get snagged on brush or even put some rocks in your pack when you go to pee. Yes to the helmet, held on by both side compression straps. I have used it, the tightened compression straps, to hold a full wet suit, with the rest of the suit cinched on both sides and laid over the top of the pack. Also another trick is to stuff some extra clothing, jammed in between the pack and the inside of the helmet. Yes, it is a bit of a pain to repack the thing every time you really need to get inside the pack (little things can be gotten out without the house of cards collapsing). Other little tricks? Wear something and you don't have to carry it. Before standing up in the morning, on with the shorts, on with the socks, on with the knee pads (use as shin protectors for approaches), then on with the shoes. See what % of the time you remember to get the knee pads on, before putting the shoes on. Also wearing your harness is a trick that has been utilized. If you don't like "clanking" around too much, some hardwear can still go in the pack. With the scuttlebutt, it even adds some warmth, if you normally traipse around in shorts on cold mornings. Great pack. The handle on top, which mitigates the pack twisting in tight spots, is sheer genius. Ram
Imlay packs might be one of the few that still offers uncoated nylon fabric. Maybe time to move to coated? Probably immensely cost prohibitive but that Cilogear fabric used in their MOB Worksacks is nearly indestructible. Mine has an enormous amount of use and still has no holes in it. Alpine climbing use but not canyons. Can't imagine trying to sew one with that material. Whatever Russ/Fish uses on his packs is pretty durable stuff. I tried to talk him into adding a waist belt to one of his custom packs but he wasn't havin' it. Atom Smasher has been a great haulable pack for climbers. Ditto the Metolius material. I'd ditch the zipper and use a top roll down closure secured with a metal buckle (ala Metolius). You could always replaced the sewn on side straps with those metal clips that take straps. That way folks could customize and put whatever length of strap they wanted or just removed the straps. Could add one near the bottom to give the option to really overload that little pack. The lep is a nice size. Likely great for hauling a power drill...(!). Could be a good option for replacing my similar sized pack (old BD bullet) I use to haul (that has a blown zipper). You need some pic's of the Lep in use! Come on, folks, let's see 'em! (That pic of the little dog in the pack was pretty cute).
I've carried the same leprechaun pack almost every day now for over 5 years. They are perfect size for my laptop and all of my file folders. I think we own 5 or 6 of the packs and they are the go to pack for tight canyons, short hikes, storage bags in jeeps for offroading. Definitely the most versatile and most used packs we own. Yet to wear one out.
Possible vertical MOLLE stitching along the hip belt? Would allow for very easy/cheap "pocket" attachment of the wide variety of MOLLE pouches out there. I like having chapstick and my phone on my waist and not in my pocketses.