Ultimate Guide：How to Make a Roll Top Backpack

Creating your own roll-top backpack is an exciting and rewarding project. With just a few materials and some basic sewing skills, you can craft a unique and practical backpack that perfectly suits your adventure needs.

Whether you’re looking for a weather-resistant hiking companion, a sturdy climbing bag, or a stylish urban pack, this how to make a roll top backpack guide will walk you through each step of the process. From selecting materials to the final stitches, you’ll receive detailed instructions to ensure you complete the project successfully.

Let’s get started!

Gathering Materials and Tools

Before diving into the construction process, it’s essential to gather all the necessary materials and tools. This section will cover everything you need to get started on your DIY roll top backpack project.

Fabric Selection

Choosing the right fabric is crucial for the durability and functionality of your backpack. Consider the following options:

• 1000D Cordura: Highly durable and water-resistant, ideal for the backpack’s bottom and high-wear areas
• 500D Cordura: A lighter alternative that still offers good durability
• Ripstop nylon: Lightweight and tear-resistant, suitable for the main body of the pack
• Silnylon: Excellent for waterproofing, can be used as a liner

When selecting your fabric, keep in mind the intended use of your backpack and the level of durability required.

Webbing and Hardware

You’ll need various types of webbing and hardware to construct the straps and closures of your backpack:

• 1-inch medium-weight webbing: For shoulder straps, roll top closure, and other load-bearing areas
• 1-inch lightweight webbing: For gear loops and non-load-bearing attachments
• 1-inch grosgrain ribbon: For binding seams
• Buckles: Slide release buckles for the roll top closure and sternum strap
• Ladder locks: For adjusting shoulder straps
• Plastic tubing: To create rigid gear loops

Additional Materials

Other materials you’ll need include:

• Foam: For padding the shoulder straps (1/4 to 3/8 inch thick)
• Thread: Heavy-duty polyester or nylon thread suitable for outdoor gear
• Sewing machine needles: Choose needles appropriate for heavy fabrics
• Scissors: Sharp fabric scissors for precise cutting
• Measuring tape and marking tools: For accurate pattern creation and fabric cutting
• Seam ripper: For correcting any mistakes

Optional Materials for Customization

Depending on your desired features, you might also want to include:

• Rigid frame material: Corrugated plastic or aluminum rod for added structure
• Interior pockets: Additional fabric for organizing gear
• Reflective tape: For increased visibility in low-light conditions

Planning Your Backpack Design

Before cutting into your fabric, it’s crucial to plan out your backpack’s design. This section will guide you through the process of creating a pattern and determining the size and features of your pack.

Determining Size and Capacity

Consider the following factors when deciding on the size of your backpack:

• Intended use (day hikes, multi-day treks, urban commuting)
• Your body size and frame
• Typical gear load

A good starting point for a versatile roll top backpack is approximately 20-25 liters in capacity. This size works well for day hikes and urban use while still being manageable to construct.

Creating a Paper Pattern

To ensure accuracy in your fabric cutting, create a paper pattern first:

1. Sketch out the basic shape of your backpack on large paper or newspaper
2. Include measurements for the main body, bottom panel, and shoulder straps
3. Add seam allowances (typically 1/2 inch) to all pattern pieces
4. Cut out the pattern pieces and test-fit them together

Customizing Features

Consider adding these features to enhance your backpack’s functionality:

• External pockets for water bottles or quick-access items
• Internal sleeve for a hydration bladder or laptop
• Compression straps to stabilize loads
• Daisy chain or MOLLE webbing for attaching gear
• Hip belt for improved weight distribution

Cutting and Preparing Fabric

With your pattern and materials ready, it’s time to start cutting your fabric. This section will guide you through the process of transferring your pattern to the fabric and preparing the pieces for assembly.

Laying Out the Pattern

Follow these steps to efficiently lay out your pattern:

1. Wash and iron your fabric if necessary to prevent shrinkage later
2. Fold your fabric in half, ensuring the grain lines are straight
3. Pin your pattern pieces to the fabric, paying attention to the fabric’s direction and any print alignment
4. Mark any notches or alignment points on the fabric using chalk or fabric markers

Cutting Fabric Pieces

When cutting your fabric:

• Use sharp scissors dedicated to fabric cutting
• Cut slowly and accurately along the pattern lines
• Label each piece as you cut it to avoid confusion later
• Keep fabric scraps for potential repairs or smaller components

Preparing Shoulder Strap Materials

For comfortable shoulder straps:

1. Cut two pieces of foam to the desired width and length
2. Cut fabric to cover the foam, allowing extra for seam allowance
3. Prepare webbing for the adjustable portion of the straps

Organizing Cut Pieces

To stay organized:

• Group cut pieces by their function (main body, straps, pockets)
• Keep small pieces like webbing and hardware in labeled bags or containers
• Double-check that you have all necessary pieces before beginning assembly

Constructing the Main Body

The main body of your roll top backpack forms the core structure. This section will guide you through assembling the primary components of your pack.

Sewing the Front Panel

Begin with the front panel of your backpack:

1. If adding external pockets, attach them to the front panel first
2. Sew any reinforcement patches or daisy chains to the front panel
3. Prepare and attach gear loops if desired

Assembling the Back Panel

The back panel requires special attention for comfort:

1. If using a frame sheet, create a pocket on the interior of the back panel to hold it
2. Attach shoulder strap anchors securely, reinforcing with extra stitching
3. If including a hip belt, create attachment points or a sleeve for it

Joining Side Panels

Connect the side panels to create the three-dimensional shape:

1. Pin side panels to the front panel, aligning any markings
2. Sew the sides to the front, using a sturdy straight stitch
3. Repeat for the back panel, creating the basic “tube” of the backpack

Adding the Bottom Panel

The bottom panel adds structure and durability:

1. Pin the bottom panel to the lower edge of the assembled body
2. Sew around the perimeter, reinforcing corners for added strength
3. Consider adding protective patches to high-wear areas of the bottom

Creating the Roll Top Closure

The roll top closure is a defining feature of this backpack style. This section will explain how to construct and attach this versatile closure system.

Preparing the Roll Top

To create the roll top:

1. Cut a rectangle of fabric for the extension above the main body
2. Hem the top edge of this piece for a clean finish
3. Attach webbing along the sides for the closure system

Attaching the Roll Top

Securely join the roll top to the main body:

1. Pin the bottom edge of the roll top to the top of the main body
2. Sew around the circumference, using a double row of stitching for strength
3. Reinforce the connection points where the closure webbing meets the main body

Installing Closure Hardware

Add buckles and adjusters for the roll top:

1. Attach male buckle ends to the webbing on one side of the roll top
2. Sew female buckle ends to corresponding points on the opposite side
3. Include adjusters on one side to allow for variable capacity

Testing the Closure

Before proceeding, test the roll top closure:

1. Roll the top down several times to ensure smooth operation
2. Check that the buckles align properly and engage securely
3. Adjust the placement of hardware if necessary for optimal function

Crafting Comfortable Shoulder Straps

Well-designed shoulder straps are crucial for comfort when carrying your backpack. This section will guide you through creating ergonomic, adjustable straps.

Shaping the Straps

To ensure a good fit:

1. Cut your chosen foam to a tapered shape, wider at the shoulders and narrower at the bottom
2. Shape the fabric covering to match, allowing extra for seam allowance
3. Consider adding a slight curve to the straps for improved ergonomics

Assembling the Straps

Put together your shoulder straps:

1. Sew the outer fabric layer, leaving one end open
2. Turn the fabric right side out and insert the foam
3. Close the open end and topstitch around the entire strap for a finished look

Adding Adjustment Hardware

Make your straps adjustable:

1. Attach ladder locks to the bottom of each strap
2. Sew webbing to the lower part of the backpack for the adjustable portion
3. Thread the webbing through the ladder locks and secure

Attaching Straps to the Pack

Securely fasten the straps to your backpack:

1. Position the straps on the back panel, ensuring proper placement for comfort
2. Sew multiple reinforced lines across the attachment point
3. Consider adding a bar tack for extra strength

Installing a Sternum Strap

A sternum strap helps distribute weight and keeps shoulder straps in place. This section covers adding this useful feature to your backpack.

Preparing the Strap

Create a functional sternum strap:

1. Cut a piece of 1-inch webbing to the appropriate length
2. Attach a small buckle to one end of the webbing
3. Sew the other end to create a loop for sliding adjustment

Attaching to Shoulder Straps

Connect the sternum strap to your shoulder straps:

1. Determine the optimal height for the sternum strap on your shoulder straps
2. Create small loops of webbing on each shoulder strap at this point
3. Thread the sternum strap through these loops, allowing it to slide for adjustment

Adding Adjustability

Ensure a customizable fit:

1. Sew the buckle ends to allow for length adjustment
2. Test the strap’s range of motion and adjust as needed
3. Consider adding elastic sections for flexibility during movement

Incorporating Internal Organization

Internal pockets and compartments can greatly enhance the functionality of your backpack. This section will explore options for adding organization to your pack’s interior.

Designing Interior Pockets

Plan your internal organization:

1. Sketch out desired pocket placements and sizes
2. Consider including a mix of zippered and open-top pockets
3. Plan for specific items like water bottles, electronics, or tools

Constructing Pockets

Create and attach interior pockets:

1. Cut fabric pieces for each pocket, allowing for seam allowances
2. Finish the top edges of open pockets with a hem or binding
3. For zippered pockets, install zippers before attaching to the pack body

Adding a Hydration Sleeve

If desired, include a sleeve for a hydration bladder:

1. Cut a large rectangle of fabric slightly smaller than the back panel
2. Sew the sides and bottom to the interior of the pack, leaving the top open
3. Add a hanging loop at the top for securing the bladder

Attaching Organization Features

Securely install your organizational elements:

1. Pin pockets and sleeves in place inside the pack
2. Sew around the sides and bottom of each pocket, reinforcing stress points
3. Consider adding key clips or other small attachment points for gear

Enhancing Weather Resistance

To protect your gear from the elements, consider adding weatherproofing features to your backpack. This section will cover techniques for improving water resistance.

Seam Sealing

Seal your seams to prevent water ingress:

1. Apply seam sealer along all exterior seams
2. Pay special attention to areas like the bottom and roll top attachment
3. Allow sealer to dry completely before testing or using the pack

Adding a Waterproof Liner

For increased protection, consider a waterproof liner:

1. Cut a liner from waterproof fabric like silnylon, slightly smaller than the main body
2. Sew the liner into place along the top edge of the pack
3. Leave the bottom of the liner free-floating to allow for easy cleaning

Incorporating Drain Holes

Add small drain holes to prevent water accumulation:

1. Identify low points where water might collect, typically at the bottom corners
2. Create small, reinforced holes at these points
3. Consider adding grommets for durability

Final Assembly and Reinforcement

As you near completion, focus on reinforcing high-stress areas and adding final touches to your backpack. This section covers the last steps in construction.

Reinforcing Stress Points

Strengthen areas prone to wear:

1. Add bar tacks or extra stitching to strap attachment points
2. Reinforce the bottom of the pack with an extra layer of durable fabric
3. Double-stitch all seams that bear significant weight

Attaching External Features

Add any remaining external components:

1. Sew on loops for ice axes or trekking poles if desired
2. Attach compression straps to the sides of the pack
3. Include reflective elements for visibility in low light conditions

Final Inspection

Thoroughly check your work:

1. Examine all seams for missed stitches or weak points
2. Test all buckles, zippers, and adjustable elements
3. Stuff the pack with gear to check for any issues under load

Testing and Adjustments

Before considering your project complete, it’s crucial to test your backpack thoroughly and make any necessary adjustments. This final section will guide you through the evaluation process.

Load Testing

Put your backpack through its paces:

1. Fill the pack with a typical load of gear
2. Wear the packed backpack and walk around, noting any discomfort or imbalance
3. Test the roll top closure with various load sizes

Comfort Adjustments

Fine-tune the fit for optimal comfort:

1. Adjust shoulder strap placement if needed
2. Modify the length or positioning of the sternum strap
3. Consider adding or removing padding in specific areas

Weatherproofing Check

Verify the pack’s weather resistance:

1. Spray the packed backpack with water to check for any leaks
2. Pay special attention to seams and closure points
3. Make additional sealing adjustments if necessary

Final Touches

Add any last-minute improvements:

1. Trim excess threads and tidy up any loose ends
2. Consider adding a label or personal touch to mark your creation
3. Take photos to document your accomplishment and inspire future projects

Conclusion

Thank you for reading and I hope this how to make a roll top backpack will help you.

By following this comprehensive guide, you’ve created a custom roll top backpack tailored to your specific needs and preferences. With proper care and maintenance, your handmade pack will accompany you on countless adventures, serving as a testament to your craftsmanship and creativity.

Remember, the beauty of DIY projects lies in the ability to refine and improve your design over time, so don’t hesitate to make adjustments or create new versions as you gain experience and insight into your backpacking needs.