Dana Design ArcLight Programming manual

1
Quick Start Instructions
If you bought your new ArcLight™ pack through a dealer who fitted the pack
to you, follow these brief instructions to double-check that your pack is adjusted
properly. If you would like a full description of how to fit the pack yourself, see
Sizing and Fitting ArcLight™ Packs on page 11.
1. Make sure the hipbelt is positioned at the very bottom of the slot behind the
lumbar pad. If it’s not, reach between the belt and lumbar pad, break loose the
hook-and-loop and reposition the belt.
2. Load the pack with a reasonable amount of weight (25 to 40 pounds). Be sure to
fasten and tighten the internal load-control strap — this is the strap with a yellow
buckle found inside the pack bag near the top.
3. For maximum comfort, it is imperative that you observe the following ritual when
fitting the pack and each time you put the pack on. First, loosen the hipbelt trim
straps and shoulder-pad lift straps. Now put the pack on and adjust the straps in
the following order:
1. Center the hipbelt on your hip crests and tighten the belt.
2. Tighten the main shoulder straps comfortably snug.
3. Firmly tighten the hipbelt trim straps — this is crucial to obtain the best
possible performance from your ArcLight™ pack.
4. Retighten the main shoulder straps.
5. Lightly tension the shoulder-pad lift straps.
6. Place the sternum strap in a comfortable position on your upper chest and
snug it lightly.
4. Now check off the following points using the ‘Quick Start Fitting’ illustrations on
the left as a guide. Be sure you adopt a backpacking position by bending slightly
forward at the hips.
a. The back panel of the pack should closely follow the contours of your back.
b. The upper ends of the shoulder pads (not the unpadded Stretch Adjusters) should
terminate one to two inches below the junction of your shoulders and neck.
c. The Stretch Adjusters should form a smooth extension of the framesheet up to
the shoulder pads.
d. The curves in the shoulder pads should swing outward around your neck and then
inward at your upper chest before sweeping outward again to avoid the breast area.
e. The lower end of the shoulder pads should terminate approximately two inches
below your armpits.
f. The sliding buckle where the shoulder-pad lift strap exits the shoulder pad
should be at the top of your shoulder.
g. The sternum strap should cross the middle of your upper chest in a comfort-
able position.
h. The hipbelt’s pads should extend past the front points of your hipbones by an inch
or so, but not be so long that they prevent the belt from being tightened fully.
If everything checks out okay, you’re ready to load the pack for real and hit
the trail! If something feels uncomfortable, see Sizing and Fitting ArcLight™ Packs,
on page 11, for detailed instructions.

2
Introduction
Thank you for purchasing a Dana Design® ArcLight™
pack. This owner’s manual will tell you how to use the
many features we build into our packs. It will also tell
you how to select the correct size pack, hipbelt and
shoulder pads, how to assemble and adjust the pack
and how to make sure the pack fits you. Adjusted and
used properly, an ArcLight™ pack will give you superb
carrying comfort. Please take a few minutes to read
through this manual to learn how to use your new pack.
Your reward will be years of hiking pleasure.
Table of Contents
Attaching the Hipbelt ......................................................... page 3
Pack Features in Detail........................................................ page 4
Packing for Comfort ............................................................ page 8
Adjusting Your Pack on the Trail......................................... page 10
Sizing and Fitting ArcLight™ Packs..................................... page 11
Sizing Chart ..................................................................... page 14
Bending the Aluminum Stay............................................... page 15
Caring For Your Pack ......................................................... page 16
Buckle Threading .............................................................. page 17
Dana Design® Pack Accessories........................................... page 18
Warranty ......................................................................Back Cover

3
Attaching the Hipbelt.
Attaching the Hipbelt Trim Straps.
(1) Thread the strap from its hipbelt attachment point up
through the bottom of the buckle, (2) over the visible bar,
(3) then back down through the buckle and out. This end
becomes the loose end used for adjusting strap tension.
Attaching the Hipbelt
You may want to remove your hipbelt for any number of reasons: to clean
your pack, to create a HipLid™ hipsac or to reduce bulk while traveling. What-
ever the reason for removing the belt, you’ll need to know how to attach it
again properly. Here’s how:
Start with the pack right side
up and the back panel toward you.
Orient the belt so it “smiles” — so
the ends of the belt curve upward.
Insert one end of the belt behind
the lumbar pad and pull until the
belt is centered left to right and
the hook-and-loop
fastener is
engaged. By
inserting your hand
between the lumbar
pad and the belt and
breaking loose the hook-and-
loop fastener, you can insert and
remove the belt more easily. It also
helps to pull the two-inch webbing
and its associated buckle through
the slot behind the lumbar pad
before pulling the padded
portion of the belt through.
Place the belt all the way
down at the bottom of the
slot behind the lumbar pad.
Once the belt is in position,
connect the hipbelt trim straps
to the buckles at the bottom
corners of the pack’s back panel.
1
2
3

4
Pack Features in Detail
The following features are found on all ArcLight™ packs with a few exceptions.
HipLid™
A HipLid™ is a large-capacity hipsac cre-
ated by combining the pack’s hipbelt and lid.
To create the HipLid™, remove the lid
and hipbelt from the pack. As you do
this, make a mental note on the path
the lid straps follow as they pass
through the buckles. Orient the belt so it
“smiles” — so the ends of the belt curve
upward. Now, with the pocket zipper
facing up, insert the hipbelt behind the
lumbar pad on the bottom side of the
lid. Be sure the hipbelt is at
the bottom of the slot behind
the lid’s lumbar pad. Engage
the hook-and-loop fastener,
then thread the hipbelt trim
straps through the ladder-
lock buckles on the sides of
the lid. These straps compress
the load and pull the HipLid™
into your back for a stable,
comfortable ride. When you
reassemble your pack, be sure
that the ends of the hipbelt
curve upward and the hipbelt
is positioned at the bottom
of the slot behind the pack’s
lumbar pad. It’s easiest to rethread the buckles connecting the lid to the pack if
the lid is held in the “flipped open” position, as if you had opened the lid to
gain access to the main compartment. (see fig. A)
Internal Load-Control Strap
The internal load-control strap is the strap with a yellow buckle found in-
side the main compartment near the top. When passed over your load and
cinched down tight, it improves your balance by compressing and stabilizing
the load while pulling it toward your body. Before loading the pack, place the
male end of the yellow internal load-control strap buckle through the top loop
of the daisy chain. This will prevent the buckle from getting tangled in the
load as you pack. It also holds the shroud open and reminds you to buckle the
strap when you’re done. Once the strap is buckled and tightened, you can throw
an item that you want to reach quickly, like a fleece jacket, on top. Close the
shroud, fasten the lid and you’re ready to go.
The assembled HipLid™.
Fig. A — Reattaching/removing the HipLid™.

5
The Hipbelt Trim Straps
Hipbelt Trim Straps
These straps connect the hipbelt to the bottom corners of the back panel
and frame system. By tensioning the hipbelt
trim straps, you pull the bottom corners of the
framing and pack toward you, which helps
stabilize the pack.
Tensioning the hipbelt trim straps and
shoulder-pad lift straps on ArcLight™
packs also puts tension on the fiberglass
stays, bending them into an arc. These stays
actively counterbalance the weight of your
load, pulling the load forward over your
shoulders and wrapping it further around
your hips. With the tensioned flexible stays
carrying most of the weight, the central aluminum stay can retain its original,
body-hugging shape, so the load stays close to your back, no matter how much
weight you’re carrying. The closer the load rides to your back, the more upright
you can walk and the more comfortable you’ll be. Tightening the hipbelt trim
straps also hangs some of the pack’s weight from the sides of the hipbelt.
Putting firm tension on the hipbelt trim straps is crucial to obtain the best
possible performance from your ArcLight™ pack. If you want a softer-flexing
frame while carrying lighter loads, reduce the tension on the hipbelt trim straps.
Shoulder-Pad Lift Straps
These straps connect the top of the shoulder pads to the top of the back
panel. When tightened, they relieve the pressure of the shoulder pads on your
shoulders and help shift the weight down to your hips, where it belongs. They
also help stabilize the upper part of the pack. Moderate tension on the shoulder-
pad lift straps is sufficient for them to do their job. If you tighten them too
much, you’ll lift the shoulder pads completely off your shoulders and put exces-
sive pressure on the front of your chest. The sliding buckle where the shoulder-
pad lift strap exits the shoulder pad should be at the top of your shoulder.
Sternum Strap
This strap connects the two shoulder pads and should be attached roughly
11⁄2inches to 2 inches below the two protruding of your collarbone adjacent to
the top of the breastbone. It helps secure the shoulder pads in a comfortable
position as they cross your shoulders and chest. Position the sternum strap
initially so it crosses the middle of your upper chest (approximately 11⁄2to 21⁄2
inches below your collarbone). Altering the sternum strap’s position and
tension periodically during the day helps prevent muscle fatigue and pressure
points. Check out Adjusting Your Pack on the Trail, page 10, for an additional tip.

6
Compression Straps
Compression straps are the two horizontal straps located on each side of
the pack bag. They are used to compress any size load, reduce the pack’s vol-
ume when carrying a small load and attach skis, tent poles, fishing rods, etc.
Keep the compression straps snugged tight at all times to compress and immo-
bilize your load. For tips on using compression straps to lash on skis and other
long objects, see Packing For Comfort, page 8.
Daisy Chain
A daisy chain is a vertically oriented piece of webbing bar-tacked at two-
inch intervals to form a series of small loops. You can use the daisy chain to
strap on gear such as a sleeping pad or tripod. It can also be used in conjunc-
tion with an ice-axe loop to attach an ice axe.
Sleeping-Pad Straps
Sleeping-pad straps are a pair of vertically oriented straps which buckle at
the top of the sleeping-bag compartment. As the name implies, they’re nor-
mally used to attach a sleeping pad. They can also be used to relieve the ten-
sion on the sleeping-bag compartment zipper when zipping the compartment
closed after stuffing a large sleeping bag inside. Be sure the sleeping-pad
straps are tight even if you don’t use them to lash on gear; loose straps snag
easily on brush.
Sleeping-Bag Compartment Divider
The sleeping-bag compartment divider is a panel inside the pack bag which
separates the sleeping-bag compartment from the main compartment. Its pri-
mary purpose is to help keep the pack bag slim, so the load rides closer to your
back for better balance and comfort. By loosening the divider’s straps, you can
increase the sleeping-bag compartment’s volume to accommodate a very large
sleeping bag. It’s also possible to detach these straps completely to form a
single-compartment pack bag, which maximizes the pack’s volume.

7
Retractable Bottom
Packing extra heavy? Packing extra light? Our unique retractable bottom
helps in both situations. If you’re traveling light, retracting the bottom gives
you a smaller pack that still carries superbly, with the load distributed evenly
in the upper two-thirds of the pack. If you’re traveling with a bulky load,
cinching down the retractable bottom gives you an extra eight inches of space
at the bottom of the frame where you can lash on bulky items that don’t fit in-
side the sleeping-bag compartment. This works much better than lashing a
large bundle on top of the pack.
To retract the pack bottom on the Glacier, open the sleeping-bag compart-
ment and undo the sleeping-bag compartment divider from its buckles. Now
locate the two short black straps sewn to the bottom of the pack. Thread these
straps through the three-quarter-inch ladder-lock buckles attached to the back
panel about 10 inches up from the bottom and cinch the straps tight. This col-
lapses the lower portion of the pack and reduces the pack’s volume. Zip the
sleeping-bag compartment or other access zippers shut and presto! Just pack
and go.
Water Bottle Pockets
Our mesh water bottle pockets, located at the bottom of the packs side
panels, are great for just that. Liter Nalgene or bike bottles keep you hydrated
or use these pockets in conjunction with the compression straps to hold tent
poles, fly rods, etc.
The Retractable Bottom retracted.
Retracting the bottom.

8
Packing For Comfort
To obtain the greatest possible comfort from your ArcLight™ pack, you
must load it properly.
The fundamental principle is that a thin, flat load, as viewed from the side,
carries better than a fat, cylindrical load. Carrying a thin load lets you walk com-
fortably upright instead of leaning forward in a constant battle against a pack
that’s trying to pull you over backwards. Follow these suggestions to keep the load
thin and your pack riding comfortably.
1. Before you start loading the pack, be sure all compression straps are loose. Pull out
the internal load-control strap and thread the yellow buckle through the top loop of
the daisy chain.
This keeps the buckle from getting tangled in the load as you pack.
2. Place the lightest and bulkiest items in the bottom third of the pack bag, the
heaviest, most dense items in the middle third as close to your back as possible
and medium-weight items in the upper third. This weight distribution will give you
a balanced, comfortable ride.
3. Women have a lower center of mass than men. As a result, some women prefer to pack
the heaviest items a little lower than men. Experiment to see what works best for you.
4. (See illustration) Always pack your sleeping bag at the very bottom. If your pack
has a sleeping-bag compartment, you can either stuff the sleeping bag into the
compartment without its stuff sack to save weight, or you can use the stuff sack
for extra moisture protection. If you use a stuff sack, fill out the corners of the
sleeping-bag compartment
with small items such as
socks and underwear so you
use the compartment’s vol-
ume with maximum effi-
ciency.
5. (See illustration) (a) Load
food and other heavy items,
such as extra water or climb-
ing hardware, above the
sleeping-bag compartment
and as close to your back as
possible. The framesheet will
keep sharp objects from jab-
bing you in the back. (b) Sur-
round these heavy items with
clothing. This helps insulate
the food as well as insuring
that the heavy items remain
close to your back.
6. (See illustration) Put your
stove and cookset in the up-
per area of the main compartment. Surround it with lightweight items that you
might need quickly, such as a PackFly™, rainwear, or a fleece jacket.

9
7. (See illustration) Pack small necessities like your map and compass, trail or field
guide, first-aid kit, hat and gloves in the lid pocket.
8. Avoid lashing heavy items on the front of your pack, or placing heavy items in the
front pockets or BeaverTail Shovit™. Placing heavy items on the front of your pack
will throw off the balance of the pack and force you to lean forward uncomfortably.
9. Pack your gear tightly. Then tighten the compression straps to compact the load
still further. If you take some clothing out of the
pack as the temperature drops, be sure to re-tighten
the compression straps.
10. Reef down hard on the internal load-control strap in-
side the pack near the top. This strap further com-
presses the load and pulls the top of the pack into a
flat, slim profile. Once you’ve tightened the strap, put
your fleece jacket or rain gear — anything you want
to reach quickly — in on top, then close the pack’s
shroud over it.
11. Keep the sleeping-bag compartment divider strapped
in tight. It’s cut in a rectangular rather than circu-
lar shape to help keep the load flat against your
back. Without the divider in place, the pack will be-
come two or three inches thicker with only a slight
increase in volume.
12. There are many options for carrying your tent. One option is to separate the tent
body from the fly and poles. Lash the tent body (in a stuff sack) under one set of
compression straps and lash the fly and poles (in another stuff sack) under the
other set. A second option is to pack the tent body and fly together in one stuff
sack and stow it in the middle third of the pack, then lash the poles outside using
the compression straps.
13.To carry skis, lash one on each side of the pack. Start by slipping the tail of one ski
under a bottom compression strap, then wrap the top compression strap completely
around the ski before tightening the strap. Then lash the tips together with an acces-
sory strap. This creates an A-frame configuration that keeps the ski tails from jabbing
the back of your knees. Wrapping the top compression strap around the object also
helps stabilize fishing rods, tent poles and wands. If a Necessity Pocket is on the com-
pression strap, slide the ski between the pocket’s plastic frame and the pocket itself.
14. Dana Design® packs are built from extremely tough materials, but naked fabric is
no match for sharpened steel. To protect your pack when carrying skis, cut four six-
inch lengths from an old bicycle inner tube. Slip these rubber tubes over the ends
of your compression straps and position the tubes so they protect the straps and
fabric from the ski edges.
Low
(4)
Low
(7)
Med./Low
(6)
Med.
(5b)
High
(5a)
General packing weight regions.

10
Adjusting Your Pack on the Trail
For maximum comfort, it is imperative that you follow this ritual each
time you put the pack on.
Before picking up the pack, make sure that the hipbelt trim straps and
shoulder-pad lift straps are loose. Now put the pack on making sure to lift the
pack by the haul loop and not the shoulder pads. Center the hipbelt over your
hip crests and tighten it, then tighten the main shoulder straps. Next —this is
important —tighten the hipbelt trim straps by pulling forward and up. Re-
tighten the main shoulder straps, then snug the shoulder-pad lift straps a
moderate amount. The sliding buckle where the shoulder-pad lift strap exits the
shoulder pad should be at the top of your shoulder. Position the sternum strap
in a comfortable location on your upper chest (approximately 11⁄2”to 21⁄2”
below top of sternum) and tighten it lightly.
As a final suspension adjustment, try this “tweak”to improve the shoulder
pad fit. Once all the hipbelt and shoulder straps are snug, slightly loosen the main
shoulder straps, which will transfer more weight to your hips. It will also cause the
pack to fall away from your back. To solve this, do not tighten the shoulder-pad lift
straps; instead, retighten the sternum strap. This pulls the pack closer to your back
without putting more weight on your shoulders. It also allows the shoulder pads to
ride closer to the center of your body, which reduces pressure on the relatively
weak outer portion of your shoulders and redistributes the load to your ribcage.
When the pack is properly adjusted, the majority of the pack’s weight
should ride on your hips, with the remainder distributed between your shoul-
ders and your back. You can vary that ratio, however, by adjusting the hipbelt,
main shoulder straps, shoulder-pad lift straps and sternum strap. To shift more
weight to your shoulders, for example, loosen the hipbelt slightly. Changing the
ratio periodically during the day, particularly with a very heavy load, helps pre-
vent fatigue and pressure points.

11
Sizing and Fitting ArcLight™Packs
A Note on Fitting
While it is possible to size and fit an ArcLight™pack by yourself, we
highly recommend that you visit a Dana Design®dealer who we have trained to
size and fit our packs. If you have any questions which cannot be answered by
a dealer, please call our Customer Service Department at 888-357-3262. We’re
open Monday through Friday, 8 a.m. to 5 p.m. Pacific Time.
Selecting the Correct Size ArcLight™Pack
ArcLight™packs are available in three sizes: XS/S, M/L and L/XL. The pack
size label is sewn into the side seam next to the back panel. To determine the
correct size, you must first measure your torso length. Ask a friend to use a
flexible tape measure (a tailor’s tape works best) to measure along the surface
of your back. First, locate your seventh cervical vertebra (the most prominent
bump at the base of your neck when you tilt your head all the way forward).
This vertebra lies at the junction of your shoulders and neck. Now, with your
head upright, not tilted forward, measure from that vertebra to a horizontal
line across your back connecting the outward protrusion of your hip crests.
Once you know your torso length, use the chart on page 14 to determine the
correct pack size.
Please don’t try to predict your torso length from your height. If you have
any questions, or feel you are between sizes, please contact your nearest
dealer. Measuring your torso length is just a starting point. The actual pack
size will be determined by how the pack fits your back.
7th Vertebra
Hip Crest
Take your waist
measurement here.
Torso length
measurement
area.
Aluminum
Stay

12
A Stretch Adjuster
Adjusting ArcLight™packs
ArcLight™packs use our patented Stretch Adjustment System™to fine-
tune the fit once you’ve selected the right size. The Stretch Adjustment Sys-
tem™is ultimately simple, yet infinitely flexible. It allows you to adjust the ef-
fective shape of the pack’s framesheet to fit your torso length and shoulder
shape. In other words, you can not only adjust the torso length within a 31⁄2”
range, but also the distance between the shoulder straps and the angle at
which the shoulder straps exit the pack bag and curve over your shoulders.
Our Stretch Adjusters are the heart of this system. Each one consists of a
strip of High Density Polyethylene framesheet material sewn with a fabric ex-
tension of our soft edge shoulder pads. These strips of framesheet material
serve as extensions of the framesheet; in effect, they lengthen the framesheet
so it reaches up to the upper ends of the shoulder pads. Stretch Adjusters are
anchored to the back panel of the pack with extremely strong hook-and-loop.
Note that a complete shoulder-strap assembly consists of a Stretch Adjuster at-
tached to an appropriate size of Silhouette Shoulder Pad. The Stretch Adjuster
has no padding, so it is not designed to be used
alone.
To check the fit of your new pack and determine
if it needs to be adjusted, refer to the Quick Start
instructions on page 1. If the shoulder pads are
not positioned correctly, slip your hand in be-
tween the Stretch Adjuster and the back panel
and break loose the hook-and-loop. You can now
adjust the torso length, the distance between the
shoulder pads and the angle at which the pads
exit the back panel. At the shortest possible
torso length, the shoulder pads will just about
touch the top of the pack’s back panel. At the
longest possible torso length, the hook-and-
loop on the Stretch Adjusters should still be
hidden behind the back panel. If you have
hook-and-loop showing above the back panel,
you need a larger size pack. If you almost have hook-
and-loop showing, you should consider trying on a
larger size. When you think you’ve got the right con-
figuration, double-check that the right-hand Stretch
Adjuster is in the same position as the left, then press the hook-and-loop back
together. Note that there is a horizontal strap near the top end of the shoulder
pads that connects the Stretch Adjusters. On rare occasions, it may be neces-
sary to adjust this strap to an appropriate length to keep the shoulder pads a
comfortable distance apart. The sliding buckle where the lift strap exits the
shoulder pad should be at the top of your shoulder.
Now try the pack on again. You can readjust it as many times as you need
until it rides comfortably.

13
C
o
r
r
e
c
t
1"- 2"
Top of
Shoulder
End of
Shoulder
Pad
W
r
o
n
g
-
S
t
r
e
t
c
h
A
d
j
u
s
t
e
r
t
o
o
l
o
w
more than 2"
Top of
Shoulder
End of
Shoulder
Pad
W
r
o
n
g
-
S
t
r
e
t
c
h
A
d
j
u
s
t
e
r
t
o
o
h
i
g
h
less than 1"
Top of
Shoulder
End of
Shoulder
Pad
When the Stretch
Adjuster is correctly
positioned, it causes the
shoulder pad to wrap
around the shoulder so
that the end of the
shoulder pad is 1”to 2”
below the top of the
shoulder.
If the Stretch
Adjuster is too high, the
shoulder pad will be
unable to wrap around
the shoulder enough to
support the load
properly.
When the Stretch
Adjuster is positioned too
low, it forces the shoulder
pad to drop more than 2”
below the top of the
shoulder. This causes the
shoulder pad to fit
incorrectly or may lead
you to choose
the wrong size of
shoulder pad.

14
Selecting the Right Size Hipbelt for Your ArcLight™Pack
ArcLight™packs use our ArcLight™Hipbelt, which is available in three
sizes: small, medium and large. To determine the correct size hipbelt, you must
measure your hip circumference. Again, a tailor’s tape works best. Remember
that the hipbelt is wrapping around and cupping over your hipbones, so be sure
to measure the circumference of your hips, not your stomach (see diagram on
page 11). Once you have determined your hip circumference, use the chart on
this page to select the correct size belt. When sized properly, the pads should
extend past the front points of your hipbones by an inch or so, but not be so
long that they prevent the belt from being tightened fully.
Selecting the Correct Size Shoulder Pads
All ArcLight™packs use our Soft Edge Shoulder Pads. These pads are avail-
able in three sizes: small through large. In general, many women use small
pads while taller women (5' 8" and up) may need medium pads. Exceptionally
tall or thick-chested men could use extra-large pads, which are only available
in Burly. When properly sized, the lower end of the pad will be approximately
two inches below your armpit.
The pack size label is found along the side seam next to the mesh backpanel.
FRAME SIZES DANA DESIGN®Sizing Chart BELT SIZES
Back Measurement Size Pack Series Waist Measurement Size
up to 18" (46 cm) XS/S ArcLight Series up to 30" S
18"-21" (46 -53 cm) M/L 30"-36" M
21" (53 cm) and over L/XL 36" and over L

15
Bending the Aluminum Stay
ArcLight™frames include a single aluminum stay that parallels your spine
and gives the pack its shape. We pre-bend our stays to a shape that fits the
majority of people. When properly sized and fitted, a Dana Design®pack should
closely conform to the shape of your back. If it doesn’t, you should bend the
stay to match your back’s contours.
If you need to modify the stay’s shape, we strongly urge you to seek out a
Dana Design®dealer. All of our dealers have been trained in the proper fitting
of our packs. If that’s impossible, you can test your agility by using a mirror or
test a friendship by employing a friend.
Removing, Rebending and Replacing an ArcLight™Stay
To remove the stay, look between the padded portion of the back panel
and the cloth pack bag. Pull up the hook-and-loop flap covering the top of the
padded back panel and locate the vertically oriented piece
of 11⁄2inch webbing. The upper end of that piece of web-
bing is folded over the end of the stay. Pull the stay
straight up to remove it. Now pretend you have a
weighted pack on your back by adopting a slight
forward bend at the hips.
Position the stay along your spine so that the
bottom is two inches below a line connecting your
hip crests. The location of the upper end will vary,
depending on your torso length. The stay should
closely follow the curve of your back.
It’s easiest to bend the stay smoothly, without
creating kinks, if you bend it over a broad, rounded
surface like your thigh. Once the stay is shaped, re-
insert it into the 11⁄2inch webbing slot sewn to the framesheet, being careful
to put it in right side up and with the lumbar and top curves facing the correct
way. Fold the end of the 11⁄2inch webbing over the end of the stay, then fold
down the fabric flap.

16
Caring For Your Pack
Cleaning Your Pack
Packs lead a hard life. They get dragged through the mud and tossed into
the back of pickup trucks. You can extend the life of your pack by cleaning it
when necessary. Start by removing the aluminum stay (see Bending the Stay, at
the top of this page) and the hipbelt (see Attaching the Hipbelt, on page 3).
You’ll be able to clean the hipbelt much more effectively if it’s not attached to
the pack. Now turn the pack bag upside down and shake out all the accumulated
trail grit. Use a soft, dry brush to sweep out all the particles and dislodge any-
thing stuck to the surface. If spot-cleaning is all you need, try Energine or a
similar 100% naphtha product, available at most supermarkets and drugstores.
If the whole pack needs cleaning, follow this procedure. First, fill a bath
tub half full with lukewarm water. Add 1/8 of a cup of mild soap (Palmolive
dishwashing liquid and Woolite are good choices). Do not use detergents or
harsh soaps, which can damage the fabric’s waterproof coating. Soak the
pack bag and hipbelt for 10 minutes, then use a soft hand brush or sponge to
gently scrub the hipbelt and outside of the pack bag. Do not scrub the inner,
coated side. Thoroughly rinse the pack bag and hipbelt with cool water, then
line dry them away from direct sunlight. Never use a dryer! Never put your
pack in a washing machine!
Your Pack is not a Haul Bag!
We build all our packs from very tough materials. However, they are not
haul bags! If you tie your pack to the end of a rope and haul it up a rock wall,
you will put holes in it! Front pockets are particularly vulnerable to this form of
abuse. If you must haul your pack, put it inside a haul bag first —then expect
to replace the shredded haul bag every few trips.
Avoiding animal damage
Animals can destroy a pack. To prevent damage, remove all food, food
wrappers and anything else that has an odor. Wash your pack occasionally to
remove food debris, odors and the salt left behind when perspiration evapo-
rates. Many animals love to chew on salty items. When in camp, open all zip-
pered compartments and, if possible, hang the pack from a tree limb to further
discourage “mammalian mastication.”
Storing Your Pack
Before storing your pack, loosen the shoulder-pad lift straps and tighten
the main shoulder straps completely so that the shoulder pads are held flat
against the back panel. This prevents the pads from developing a permanent
kink. Loosen the hipbelt trim straps to relieve tension on the hipbelt. If stor-
age space is at a premium, remove the hipbelt and tuck it inside the pack bag.
Make sure the pack is clean and dry, then store it in a cool, dry place away
from direct sunlight. Avoid storing your pack in a garage or shed where critters,
either domestic or wild, can get at it.

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1
2
3
1
2
3
1
2
3
4
2
1
3
Buckle Threading
Ladder-Lock Buckle
(1) Thread the loose end of the
strap through the bottom of the
buckle, (2) over the visible bar, (3)
then back down through the buckle
and out. The loose end is the end
used for adjusting strap tension.
(4) This loop attaches the buckle
itself to a fixed point on the pack and is
shown here for reference only.
Tri-Glide Buckle
(1) Thread straps up through the
bottom of the buckle, (2) over the
center bar, (3) then back down
through the opposite slot and out
the bottom.
Side-Release Buckle
This buckle is threaded in the same way as a ladder-lock buckle. (1) Thread
the loose end of the strap up through the bottom of the buckle, (2) over the
center bar, (3) then back down through the buckle and out. The loose end is
the end used for adjusting strap tension.

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Dana Design®Pack Accessories
We build a full line of pack accessories that can make your trip more
convenient and enjoyable.
Ribs
Ribs are a convenient and comfortable way to
carry items you want to reach quickly, such as a
camera, map or water bottle. Ribs attach firmly to
the lower webbing of the shoulder straps, so they
don’t jiggle and bounce when you walk. Unlike
hipbelt-mounted pockets, Ribs won’t bang into your
thighs with each step.
PackFly™
Hiking in monsoons or the occasional
thunderstorm? Keep things dry with the
Packfly. Features a built in hood so you
keep the pack, your head and most impor-
tantly the area where your
pack meets your back dry
and comfy. When the rain
stops, it stuffs into any
integral stuffsack.
Derivatives include
a Killer B Packfly and a
Framefly.
Necessity Pockets
If you need extra capacity, consider buying our
Necessity Pockets, which attach to the compression
straps of almost any pack. You can either mount the
pocket outside the compression straps or underneath
them. Placing the pocket outside the straps allows
you to lash items under the straps. If you attach the
pocket under the straps, the plastic frame of the
pocket compresses the pocket’s contents against the
pack, which prevents the contents from shifting.
Wet Rib™

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Travel Pocket™
When traveling on airplanes with your
pack as checked luggage, we strongly
recommend stowing the pack inside our
Travel Pocket™. Not only does the Travel
Pocket™protect the pack from conveyor
belts and baggage gorillas, but it doubles
as a makeshift rainfly and a second piece of
luggage. Lastly, it disguises your pack when
you’re hanging out in an urban jungle.
Available in two sizes, Regular and Behemoth.
BeaverTail Shovit™
You can use this multi-talented
accessory to lash on an avalanche shovel,
snowboard, big tripod or pair of telemark
boots –practically anything that won’t fit
conveniently inside the main compartment.

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Window Stuffers
For the ultimate in organization, Window Stuffers not only compartmentalize
your gear, they also give cues for at a glance identification. Three sizes for
versatility. Ideal for first aid kits, repair kits, spice kits, anything where easy
identification is useful.
Compression Stuffers
When your gear threatens to explode out of your pack, Compression Stuffers are
the ideal containment system. Three sizes will control a variety of bulky items.
Not meant for use in nuclear power facilities.