Exo K4 Pack Issue

As a follow up, I took Taudisio’s advice and ordered the Z pack sewing repair kit. It weighs nothing and will be in my pack going forward.

I repaired the rip myself and it works fine. I will caution folks, the fabric is so tough and the needle gauge is so large, that I needed a pliers to actually get the needle through the fabric. I think it would be possible, but very difficult and time consuming to do by handView attachment 908143

I’m not familiar with these packs, but is that buckle supposed to go there just underneath the rip? Or is it supposed to attach to the loop above it? could be why it’s ripping?



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Are you trying to put the bag back into the stays after meat is loaded? If not what are you doing to rip these?

Nope, never used the meat shelf. The bag tore at bottom of the pocket both times while hiking with weight in the bag itself. That tear was then enough for the stave to pop out continuously while walking.

On the smaller bag, I repaired with Z Pack sewing kit and that seems to work fine.

I haven’t addressed the tear on the larger bag yet as I’m still on road coming back from the hunt. I’ll take a pic when back.

IMO, these stave pockets should be made longer and sturdier to prevent both the tearing and potential for stave popping out. It would be minimal weight difference and manufacturing cost difference.

Again, I may be an idiot and only one having these issues, but I doubt it.
 
I’m not familiar with these packs, but is that buckle supposed to go there just underneath the rip? Or is it supposed to attach to the loop above it? could be why it’s ripping?



View attachment 922323

Your setup looks fine. I’m talking about the fabric pockets for the frame staves, just above the buckles.

That said, the stave pockets on both my packs are sewn/cut a bit differently than yours. Perhaps it’s a sewing issue with a specific batch? I’ll post a pic in a few days showing the tears. Both occurred in same place.
 
Nope, never used the meat shelf. The bag tore at bottom of the pocket both times while hiking with weight in the bag itself. That tear was then enough for the stave to pop out continuously while walking.

On the smaller bag, I repaired with Z Pack sewing kit and that seems to work fine.

I haven’t addressed the tear on the larger bag yet as I’m still on road coming back from the hunt. I’ll take a pic when back.

IMO, these stave pockets should be made longer and sturdier to prevent both the tearing and potential for stave popping out. It would be minimal weight difference and manufacturing cost difference.

Again, I may be an idiot and only one having these issues, but I doubt it.

I have seen it but it was caused by forcing the bag back over the stays when a load is in the shelf. That’s weird my pack is loaded with 50# right now and there is little to no load on the stay pocket. I would reach out to EXO.
 
Just got back. Here are the pics. Both tabs of the 7200 split on the outside, exact same spot as the smaller bag.

So pic order is:
1. 7200 split left side
2. 7200 spit right side
3. 3600 repaired right side with Zpack sewing kit
4. Undamaged 3600 tab

@S&S ARCHERY , does the undamaged tab look normal? What I'm wondering is if these came out of the sewing room flawed (possibly just a bad batch), or if it's a design issue.

Thanks
 

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Just got back. Here are the pics. Both tabs of the 7200 split on the outside, exact same spot as the smaller bag.

So pic order is:
1. 7200 split left side
2. 7200 spit right side
3. 3600 repaired right side with Zpack sewing kit
4. Undamaged 3600 tab

@S&S ARCHERY , does the undamaged tab look normal? What I'm wondering is if these came out of the sewing room flawed (possibly just a bad batch), or if it's a design issue.

Thanks
This is definitely one of those cases where I would love to be on a hunt with you and see what's happening / how you are using the pack. This issue continues to be extremely rare for us and to have it happen twice to you is hard to wrap my head around. The frame pockets don't just tear easily, it takes a lot of force to get them to do that. As you experienced with just how tough that fabric is trying to get the sewing needle into it.

I know you have been emailing Jake so if you can please send any photos of you hunting and wearing the pack I would like to see them. Regardless we'll get you taken care of and get these fixed up for you.

Steve
 
This is definitely one of those cases where I would love to be on a hunt with you and see what's happening / how you are using the pack. This issue continues to be extremely rare for us and to have it happen twice to you is hard to wrap my head around. The frame pockets don't just tear easily, it takes a lot of force to get them to do that. As you experienced with just how tough that fabric is trying to get the sewing needle into it.

I know you have been emailing Jake so if you can please send any photos of you hunting and wearing the pack I would like to see them. Regardless we'll get you taken care of and get these fixed up for you.

Steve

Thanks Steve, appreciate all you do. I'll self repair this season, and then send in the bags after season for formal repair.

Just to understand, does the undamaged pocket look normal? Or does it look like sewing shop missed a step? It's weird as it looks a bit "unfinished" on this end, which is why i'm curious.

FWIW, several others have reached out on DM's with same issue.

Thanks again for supporting your product and for the communication
 
Thanks Steve, appreciate all you do. I'll self repair this season, and then send in the bags after season for formal repair.

Just to understand, does the undamaged pocket look normal? Or does it look like sewing shop missed a step? It's weird as it looks a bit "unfinished" on this end, which is why i'm curious.

FWIW, several others have reached out on DM's with same issue.

Thanks again for supporting your product and for the communication

Everything looks correct to me. This isn't a case where a sewing step getting missed is causing the issue. This is the fabric tearing and again that stuff is so tough it's exceptionally rare for it to happen. Doing quick math we are talking .0008 percent of packs sold over the last 3+ years. And of those people it's happened to almost all of them are people trying to put the bag back on the frame with a load in the load shelf.

Definitely reach out when you are ready and we'll get this all fixed for you.

Steve
 
Just got back. Here are the pics. Both tabs of the 7200 split on the outside, exact same spot as the smaller bag.

So pic order is:
1. 7200 split left side
2. 7200 spit right side
3. 3600 repaired right side with Zpack sewing kit
4. Undamaged 3600 tab

@S&S ARCHERY , does the undamaged tab look normal? What I'm wondering is if these came out of the sewing room flawed (possibly just a bad batch), or if it's a design issue.

Thanks

Same frame for the 3600 and 7200?
 
Yes, the K4 which I love. The frame and packs come separately, so you can throw whatever bag on same frame

In the one photo of the 7200 the stay pouch looks bunched up like your stay is too short I took a photo of mine as comparison.
26c874730200b93ddc9037b4bace9407.jpg
 
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