Rain cover for expedition rucksack
In preparation for springtime, and for the fact that I am about to move to a state nicknamed “Vacationland”, I have been updating my outdoor supplies. Last year I decided to scrap my internal frame backpack, along with about 30 other items, at a yard sale. This was mostly because hiking around where I live is either one of two things: a walk on a sidewalk through the woods, or a walk through a brier-filled swamp. So, I figured I’d make some money (and some room in my garage) and lighten my inventory somewhat.
Now that I am about to go back to an area where hiking and camping is actually possible, I am super excited. In preparation, I bought a new rucksack. I decided to go with the external frame this time around for a multitude of reasons. If you are familiar with hiking at all, you have probably read about the internal/external frame debate ad nauseum already, so I will abstain from arguing one way or the other. (Personally, I find the external frame far superior in terms of comfort, weight distribution, functionality, and versatility.)
The pack I bought is amazing, but it didn’t come with a rain cover. Some might argue the necessity of a rain cover for their pack, citing that a tent or tarp would do just fine. The only trouble with that is that you cannot very easily pull out your tent or tarp and cover your gear while continuing to hike in the rain. For this you need a rain cover that can quickly fit over your gear and allow you to continue on the hike despite the foul weather.
Eager to get back into homemade fabricating again, I decided to sew one myself rather than buy one.
If you would like to try this, you will need the following:
- Fabric (preferably ripstop nylon)- Measure for at least 1 foot clearance on all sides of your pack
- Bungee cord- Measure the circumference of your pack, and make the bungee just a bit smaller
- Sewing machine and basic sewing skills
- A lot of patience, and some Tylenol for the aching joints you’ll have when you are done
The first step was to cut my nylon to the size I wanted. I used a pretty thick 440 ripstop nylon with a waterproof coating on one side as the fabric of choice. I cannot remember where I bought it, but I have TONS of it left over from my homemade hammock and other projects I tackled several years ago. For the bungee I used 1/16″ bungee, which I also bought years ago and have TONS of. I measured out the bungee cord (which you can barely see lying around my pack in the picture) to be just smaller than the frame. The idea is that the bungee will have to stretch just a bit to fit over the frame, and thereby provide enough tension to keep the fabric covering the pack. The fabric has to be a decent size larger than the pack to allow for size differences in gear loads, and also for extra items that might be hanging off the frame (like an iso mat, tent, etc). Once I measured and was comfortable with the size, I cut the piece, rounding the corners to make it easier for the bungee to keep its oblong shape.
The next step was to iron the creases, which I prefer to do over pinning. If you pin the creases, you have to stop every few feet to remove the pins as you sew, and it also takes longer. I used the lowest setting on the iron, and ironed two creases. The first crease was about half a centimeter from the edge, which becomes just the folded under part to prevent unraveling later. The second crease is actually where I intend to sew the sleeve to fit the bungee.
With that done, I started sewing. Unfortunately, I was too focused on this task to remember to take a picture during the act, so instead I flubbed and took a picture after the fact. (Picture added for dramatic effect)
The next step is the long, laborious task of threading the bungee into the sleeve that you just sewed. Trying to sew the bungee in the fabric is impossible and will only result in broken needles. You have to sew the sleeve, then thread the bungee through. Trust me, I have tried.
To thread the bungee through you can either inch it along unaided, or you can poke a safety pin through it and thread the safety pin through first. Sometimes the safety pin makes it easier to thread. This project I decided to do it by hand. It took me most of a National Geographic special called “America’s Deadly Dozen” to finish the task. About an hour. Not too bad.
Once I was finished I simply pulled both ends of the bungee through until they were even, making sure to even out the fabric as well. Then I pulled both ends through a simple cord lock and tied a figure eight on the end to keep it put.
The final product weighs about an ounce and a half, and folds up to about an envelope-sized bundle. It is large enough to cover the pack plus any additional gear I might have hanging off of it, but can be tightened down very easily to cover just the pack.
It’s not very difficult or technical, but total cost was probably close to maybe $2.00 and took me about two hours total to complete. For me, that’s worth it every day, all day long.
Now I have a nice and simple rain cover for my brand new pack that I can throw into a tiny pocket and have available any time I encounter bad weather. If you give this a try, drop me a line and let me know how it came out!























