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25L Ultralight Day/Commuter Backpack Sewing Guide

Comprehensive full sewing guide and pattern for making a ultralight 25 litre backpack. A versatile and popular project.

£8.50

(Price may include tax if applicable in your country)

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Not for commercial use

Description

25L+ capacity. The internal volume is approximately 23 litre, each side pocket can fit a litre+ bottle, and the rear pocket can be up to 5 litre extra depending on fabric used.

Ultralight backpack design. Depending on your fabric choices and options included, sub 400g is achievable.

Multiple pockets that can be opted out for a streamlined bag.

Loop for a light when using the bag for cycling trips.

Removable hip belt. The pattern includes instructions for a removable webbing hip belt, with guidance on how to make a padded alternative.

Pattern Details

Comprehensive Instructions

Every step is clearly illustrated and described, and packed with helpful tips

Printable PDF Pattern

Available in US Letter, A4, and large-format paper sizes, ready for immediate printing.

Bonus Learning Tools

A free 25-page beginner’s ebook and a unique scaled practice pattern to hone your skills.

Shopping List

Full shopping and cutting list, with suggested fabrics

Suggested Materials & Hardware

A rough estimate for budgeting. A complete shopping list is included in the sewing guide.

Fabrics:

Body Fabric: 2 metres/yards (e.g., 210D-500D nylon, X-Pac™ VX21, ECOPAK™ EPX200, Robic nylon, Ultragrid, Gridstop, 1000D nylon, waxed cotton canvas)
Liner Fabric (optional internal pockets): 1 metre/yard (e.g., 70D ripstop nylon)
Spacer Mesh: <1 metre/yard (3mm/1/8 inch thick, for straps/hipbelt)
Foam: <1 metre/yard (EVA foam, 50-75kg/m3 density, 4-10mm thick)
Front Pocket Mesh (optional): <1 metre/yard (medium-weight ‘bullet’ mesh, around 250gsm)
Stretch Fabric (for front/bottom/shoulder strap pockets, optional): <1 metre/yard (e.g., Lycra, Powernet, Dyneema stretch, Venom™, Ultrastretch)

Hardware (Notions):

Nylon Webbing 3/4 inch (20mm): 5 metre/6 yard (for haul loop, top strap, front panel strap loop, roll top webbing, shoulder strap webbing)
Nylon Webbing 3/4 or 1 inch (20 or 25mm): 2 metre/yard (for hip belt attachment loops, removable hip belt)
Grosgrain 1 inch (25mm): 3 metre/3 yard (for elastic loops, front pocket hook loop, bag opening binding, internal hanging pocket, internal seams)
Grosgrain 1/2 inch (12.5mm): 1 metre (for cordlocs)
Side Release Buckles (3/4 inch/20mm): 2 (1 for bag closure, 1 for roll top webbing)
Ladderlock Buckles: 2 (3/4 inch/20mm or to match shoulder strap webbing)
Cordlocs: 3 (ITW toaster or equivalent, 2 for general, 1 for non-stretchy front pocket)
Lineloc: 2 (or 2 extra cordlocs)
Eyelets/Grommets: 2 (for side pocket water drainage)
Pack Hook or mini carabiner: 1 (optional, for front pocket)
Siamese Slik Clips (for hip belt, optional): 2 (or 2 D rings + 2 triglides)
Triglides (for hip belt, optional): 2 (or webbing retainers)
Dual Adjust Side Release Buckle (for hip belt, optional): 1
#3 or #5 Coil Zipper (optional internal hanging pocket): 1 x 9 inch (22.9 cm)
Flat Elastic 1 inch (25mm) width: 1 metre/2 yard (for stretchy front pocket, stretchy bottom pocket, stretchy shoulder strap pockets, internal sleeve)
Elastic Cord 3mm: 4 metre/4 yard (for side pockets, side panel elastics, front pocket elastic)
Velcro/Hook Loop Tape 1 inch (25mm): 1 metre/1 yard (for back panel Pad Sleeve)
Roll Top Stiffener: 1 x 14 inch (35.6 cm) piece of 3/4 inch (20mm) wide plastic (or 20mm webbing)

The sewing guide provides a comprehensive shopping and cutting list.

Capacity: 25 Litres
Dimensions: x y z
Weight (Example Pack): Approximately 450g (made from X-Pac)
Hip Belt: Removable, with options for basic webbing or full padded hip belt.
Shoulder Straps: Ergonomically designed, optional stretchy pockets

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