About a year ago, I found and bought a milsurp MOLLE II Patrol Pack. I have a number of backpacks in my inventory (too many) and have been through a few more. I keep coming back to milsurp because of the MOLLE system, which allows me to hang pouches and equipment from the pack readily. I like having pockets/pouches to stow gear and the PALS webbing makes it easy to hang gear on the outside of the pack.
The pack came without a stiffener/pad combination (a sort of frame), but the seller was kind enough to send along a set he thought would fit. I struggled to get the frame into its pocket, but made it happen. (This was expected.) But, I thought the frame was a little too long for the pocket. Nonetheless, I used it for a year (at least) before deciding to cut a little from the bottom.
A couple of weekends ago, I set up a folding table in my side yard and pulled out the frame. I carefully measured the pocket dimensions (three times), then decided to remove a half-inch from the bottom of the frame. I drew a line with a Sharpie at the cut and used a pair of electrician’s shears to make the cut. I then rounded the bottom corners to reduce the likelihood of abrading the inside of the pocket.
It was fairly easy (now that I know the process) to reinsert the frame and try on the pack. The curve that had formed at the middle of the rucksack/frame was much reduced. I decided to wear it for a while before removing any more material.
The last few outings with the pack were much improved. The bottom edge of rucksack no longer digs into my lower back a little. I think it is where I want it to be, but will continue monitoring to determine whether another adjustment is needed.
These pack are relatively rare. I had to hunt for mine. I think they were issued in the 1980s as part of the infantry pack system (see here). Because it is long discontinued and there is quite a bit of demand for milsurp packs, they are not cheap (I paid about $100US for mine) and are not common. However, I think they are worth the search.
I tried a MOLLE II Assault Pack, but found the extra size and the thinly padded straps to be not what I needed or wanted. With a reasonable loadout, the straps dug into my shoulders too much and so the pack was abandoned. Fortunately they are not expensive (or were not at the time). I also had the large ruck for a time, but it was not carryable for me.
I have also been through a number of civilian packs over the last few years. My favorite is an Osprey Stratus in the 20-liter size. It is very comfortable, if a bit small (the 36-liter is much larger). It will work well as a day pack or for an ultralight enthusiast.
As much as I love the suspension and comfort of the Stratus, the hip belt interferes with the EDC on my belt and the bottle pouches on the sides are a little small for my stainless Nalgene bottles. Therefore, I gave up on the Stratus (still have it though) and continued the search.
The milsurp canteen pouches (although not matching in ACU) readily carry a 1-liter stainless Nalgene bottle and I have one affixed to each side of my pack. The front pouch, intended to carry a standard protective mask, holds an assortment of small gear. I keep a small boo-boo kit, headnet, fire kit, mylar emergency blanket, snack, tea kit, bug juice, and a number of other small items in this pouch. The main pouch has room for overnight gear if that is needed. I generally have an emergency tarp/blanket in the main compartment and not much else. I do sometimes store a cover if the weather is cool or inclement. I removed the parachute webbing from my sample.
The shoulder straps are comfortable enough for light to moderate loads. I currently carry about 20-pounds of water and gear. I think they straps would be less comfortable once I passed about 30 pounds.
In all, I think this pack fits my use case. It is a keeper.
Life is good. I am grateful.