LITE WERKS 55L - Is this the best pack on the market?
Disclaimer: This backpack was provided to me for the purpose of pre-production testing and to offer direct feedback to the brand. As always, this review remains completely independent and reflects my honest opinions.
A First Look at the New LITE WERKS 55L Backpack
In this article, I’m sharing my experience testing LITE WERKS’ new 55-litre Ultra 200X backpack. LITE WERKS, a company founded by Dan Madden in Boulder, Colorado, provided me with this pack in mid-June 2024 for testing.
Dan has decades of backcountry experience and a long career in the outdoor industry. Frustrated with the packs he'd used over the years, he decided to take matters into his own hands. He headed to his workshop and set to work designing a pack that eliminated everything he didn’t like while incorporating the features he had always wanted. After many refinements, he finally created a pack ready to be tested in the real world. Dan believes the LITE WERKS brand will produce gear that won’t see outdoor enthusiasts needing to compromise to get a high-quality ultralight long-haul pack.
I put this pack through its paces by hiking with it for over 2,000 miles on the Continental Divide Trail. This article highlights the pack’s features and performance as I saw it, using it first-hand. With its release scheduled for the end of March 2025 at a retail price of $350-375 USD, here’s what you need to know.
Should you buy this pack?
If you’re looking for a modular, durable, spacious, and lightweight pack that prioritises comfort, this could easily become your go-to choice. However, the design features included might not be for everyone.
Overview
The LITE WERKS 55-litre backpack is designed with long-distance hikers in mind. Combining durability, modularity, and comfort, this pack offers innovative features tailored to the needs of outdoor enthusiasts. Constructed with Ultra 200X material and a fully replaceable and customisable harness system, the LITE WERKS pack is built to endure the rigours of the trail while offering versatility for different body types and preferences.
Pack Design
The pack features a 42L main compartment, complemented by a stretchy front pouch and two generously sized side pockets. These side pockets come equipped with stretchy cinch straps, ensuring a secure hold on their contents. The front of the pack boasts a large stretchy front pouch, reinforced for durability to resist ripping or punctures. Positioned above this pouch is a wax-zippered front pocket, providing additional storage for smaller items.
The main compartment utilises a roll-top closure system with two galvanised metal poppers and side-release plastic buckles, allowing it to be cinched down for a compact fit.
Inside the main compartment, the design is simple yet functional. It includes a zippered pocket for valuables, a key attachment, and slots for the specially designed removable aluminium frame, which is held securely by Velcro loops. A hook is provided to hang a hydration bladder, with a conveniently placed outlet for the hydration hose.
Additional features include two ice-axe loops and twenty-two strap attachment points, offering versatility for external gear storage. For even more customisation, hikers have the option to attach a shock cord over the front pouch, utilising twenty dedicated threading points.
Materials and Build Quality
As mentioned above, the pack is largely constructed with Ultra 200X. LITE WERKS use a stronger Ultra 100X on the bottom of the pack to reduce abrasion. Ultra X is a durable and abrasion-resistant material that serves as a compelling alternative to Dyneema Composite Fabric (DCF). Ultra 200X is the second generation of Ultra 200, a woven fabric that provides greater resistance to punctures and stretching compared to DCF while being slightly heavier but more cost-effective. Here’s a quick comparison:
Overview of the differences between Ultra 200X fabric and DCF.
Although both fabrics are listed as ultra-lightweight, DCF is slightly lighter than Ultra 200X. But, by how much? And, will you notice that weight difference?
Although it’s unlikely that once you add all of your gear to your pack you will be able to feel any extra weight, if you are the type of person who counts every extra gram, the difference between the two may be worthy of consideration.
Ultra 200X typically weighs around 3.5 oz/yd² (119 g/m²), compared to DCF, which ranges from 1.4 oz-2.9 oz/yd² (47-98 g/m²), depending on the variant. While Ultra 200X is approximately 20-30% heavier than DCF, it compensates with superior durability, abrasion resistance, and lower cost, making it an excellent choice for rugged long-distance trails. The lower material cost to the manufacturer means more features can be added compared to DCF packs, with the additional costs offset.
To put the weight difference into perspective, the table below compares the materials used by some of the more popular pack manufacturers.
Comparing Ultra 200X and DCF with 100D Nylon (Osprey Exos 48), 210D Robic Nylon (Gossamer Gear Mariposa 60 and Atom Packs Prospector), and 400D Robic Nylon (ULA Circuit)
Looking at the above table, we can see that although not as lightweight as DCF, Ultra 200X comes in above the rest of the competition. Combined with superior durability, rigidity, and water resistance, the fabric compares favourably to others in the scene.
The Ultra 200X used in the LITE WERKS pack feels robust and reliable without taking on a major weight penalty, making it ideal for ultralight gear. The base and side panels are reinforced, while the lighter fabric in other areas ensures the pack remains lightweight.
The front mesh pocket, constructed from UltraStretch fabric (from the same company that manufactures the Ultra 200X material) is reinforced with Ultra and Stretch fibres, and offers significantly more storage than similar packs, making it ideal for wet gear or quick-access items. The pocket has a DWR (Durable Water Repellant) finish which is free from any flurocarbons and PFC’s.
The side pockets are spacious and equipped with one-handed cinch closures for secure storage during challenging hikes and climbs. There is more than enough space to hold two 1L water bottles in each pocket, and with the cinch closure, you don’t have to worry about them falling out if you take a spill.
The pack shape is supported by a 6061 T6 Aluminium frame. In simple terms, it’s a 1/4” rod that is formed according to the specified design and size of the pack. The frame can be easily removed if you wish to go frameless.
Harness and Customisation
The harness system is another standout feature of this pack. This pack is the most comfortable of any I have used.
The padded waist belt is adjustable and replaceable, allowing for a customised fit. Its Velcro attachment system makes it easy to adjust the height or swap it out entirely, catering to hikers’ changing needs. I know I lose a lot of weight on long hikes, and it’s good to have the peace of mind that I can easily swap for a smaller belt if the one I start with no longer fastens tightly.
The hip belt sits behind a thick lumbar pad, ensuring the pack weight doesn’t cause pain by rubbing the lower back.
The thick S-shaped shoulder straps follow the body’s contours to prevent discomfort. They can be moved inwards or outwards for slimmer or wider builds, or replaced entirely by undoing the buckles.
The pack is also equipped with load lifters, helping to pull the pack closer to the body.
This modularity extends to the back panel, which can be adjusted up and down along the aluminium frame to provide comfort wherever the user’s upper back comes into contact with the pack.
The aluminium frame can be removed to convert the pack into a frameless model, or if you wish to compress it to act as a carry-on for air travel.
Modular Features
LITE WERKS’ commitment to modularity is evident throughout the pack. Nearly every component can be customised, replaced, or removed:
Hip Belt: Adjustable and replaceable, in a range of sizes. Straps can be adjusted in six locations to ensure a tailored fit.
Additional Pockets: Storage pockets can be added to velcro panels on the hip belt.
Shoulder Straps: Fully adjustable for width and height, with daisy chains for attaching accessories, and load lifters to reduce strain.
Straps and Buckles: Designed with looped ends for easy, one-handed adjustment, even in cold conditions. There are countless options and locations to add and remove straps on the pack for extra storage options.
The pack has the option to add useful accessories like a phone/snack pouch, elastic and zippered hip belt pockets, and a water bottle holder that accommodates bottles up to 700ml.
Trail Performance
Over the 2,000 miles I used the pack on the Continental Divide Trail, it demonstrated excellent durability and comfort. The Ultra 200X material held up flawlessly against tough terrain and adverse weather, showing no issues with water ingress.
The harness system distributed weight effectively, eliminating pressure points on shoulders, hips, or back. The lightweight support rods remained stable, even with loads exceeding 30 lbs, and showed no signs of warping.
Fit and Sizes
The pack is available in small, medium, and large sizes, and the hip belts are available in four sizes, to ensure a tailored fit. Further customisation is possible through the adjustable hip belt, which has no less than six different synch straps so it can be tightened and loosened in all the right places.
The back panel is securely attached to the pack by the aluminium frame and dual hook and loop patches, and can easily slide up or down the support rods to be secured exactly where your back meets the pack.
A medium pack averages 2lb 6oz (1077g), offering an impressive balance between weight and durability. This ensures a proper fit for hikers of all heights and body types.
Attention to Detail
LITE WERKS has incorporated thoughtful features into this pack:
One-Handed Cinches: Allow for quick strap adjustments without needing to drop everything.
Customisable: Additional straps and storage options can be quickly added and moved to a range of places on the pack.
Huge pockets: The side pockets and front pouch are much deeper and larger than those on other packs I’ve used.
Roll-Top Closure: Uses poppers instead of Velcro for a cleaner, more secure seal.
Double-Waist Buckle: Enhances pack positioning and comfort.
Replacable Parts: As most parts easily detach, they can be replaced to extend the life of your pack.
Superior Comfort: The ultra-padded harness system greatly improves comfort.
Optional straps: One must-have for me was an over-the-top Y-strap. I was pleased to see that there was the option to add one to secure my foam roll mat or a bear can.
The LITE WERKS Pack in action on the Continental Divide Trail
How it held up to the real world
The durability and comfort of this pack were notable during testing. The component straps performed well under the challenging conditions of the Continental Divide Trail, withstanding weather, dirt, and moisture effectively. The harness system maintained its comfort throughout the journey and exhibited minimal signs of wear. The padding also retained its shape and cushioning, even with significant mileage and heavier loads during longer resupply intervals.
Since the pack was in the design phase during testing, the suggestions I provided to the LITE WERKS design team were acknowledged and incorporated into the final version.
In terms of wear, I observed some areas for improvement. The fabric on the front pouch, while resistant to holes and punctures, did not hold up to abrasion as effectively as other parts of the pack. The hip belt also showed wear and abrasion, but LITE WERKS has since upgraded the fabric on the hip belt for the public release version to address this issue.
Around the lumbar support, there were signs of wear that could potentially lead to a fail point in the fabric over time. The brand has acknowledged this and indicated they have taken the issue into consideration when creating the final version.
What I Liked About the LITE WERKS 55L
Durability of Ultra 200X Material
Dyneema Composite Fabric (DCF) has long been the gold standard in ultralight backpack materials, but the emergence of Ultra 200X is making waves. Its combination of enhanced durability and cost-effectiveness offers compelling advantages. LITE WERKS is ahead of the curve in integrating this material into their design. Throughout my 2,000-mile test of this pack, the Ultra 200X fabric proved its worth, resisting abrasion, snagging, and punctures across diverse and often hostile terrains.
Comfort
The standout feature of the LITE WERKS pack is its exceptional comfort. The S-shaped shoulder straps are wider and more generously padded than those of any pack I’ve encountered. This design distributes weight across a larger area, eliminating pinch points and the red marks caused by narrower straps. Similarly, the hip belt and lumbar pad provide firm support without digging into the hips, waist, or lower back, even during long, strenuous days on the trail.
Adjustability
Customisation is another strong point. The pack offers a host of adjustments, allowing hikers to tailor the fit precisely to their body type and carrying needs. Combined with its modular design, this adaptability ensures the pack can accommodate a variety of gear setups and preferences.
Weather-Resistance
LITE WERKS is clear that this pack is weather-resistant rather than fully waterproof. However, in my experience, it performed exceptionally well, even in the harshest conditions. Not once did I notice water seeping into the pack, even during intense storms. While I recommend using a pack liner—a common practice among hikers for added protection—this pack can handle anything short of full submersion or extended water crossings.
Large storage pockets
The storage options on the LITE WERKS pack are among its most impressive features. The side pockets are spacious enough to easily hold two 1-litre water bottles securely, especially with the cinch straps that allow you to lock down anything you have stored in them. The front pouch is the largest I’ve seen on any backpack. Optional hip belt pockets are also oversized, offering two separate zippered compartments for additional storage.
The zippered front pocket above the main pouch is a handy spot for smaller items such as maps, while the large zippered pocket inside the main compartment is perfect for valuables like keys, documents, or a wallet—keeping them separate from the rest of your gear for easy access and added security.
Potential Drawbacks
There aren’t many downsides to this pack, as LITE WERKS has addressed all the feedback I provided during testing in the final design. Instead of a list of flaws, here are some factors to consider that might make this pack less suitable for certain hikers.
Size
The 55L capacity is versatile and widely favoured among long-distance hikers. However, it may not be the right choice for everyone. Some hikers prefer minimalist setups and carry smaller packs, while others need larger capacities for additional gear or supplies. For example, I’ve hiked alongside people using packs as small as 28L and as large as 85L. While the 55L size struck a perfect balance for my needs, it may not suit those at either extreme of the spectrum.
Cost
With a projected retail price of $350–375 USD, this pack falls into the higher price range for backpacks, especially compared to those made with Robic Nylon. That said, the price reflects the premium quality of materials, including the Ultra 200X fabric, and the thoughtful design. For hikers with tighter budgets, this cost might be a significant barrier.
Weight vs. DCF
If achieving the absolute lowest base weight is your priority, you’ll need to weigh the trade-offs between Ultra 200X and Dyneema Composite Fabric (DCF). Ultra 200X is heavier than DCF but offers greater durability and resistance to abrasion. For some hikers, the added grams may be worth the long-term reliability, but others might prioritise weight savings above all else.
Final Thoughts
Answering the call for everything I’ve wanted in a pack, with even more features than I’d ever thought of, the LITE WERKS 55L is the backpack I’ll be relying on for many long-distance hikes, and countless years to come.
The LITE WERKS 55-litre backpack shows promise as a versatile and durable option for long-distance hikers. Its thoughtful design, modular features, and robust construction make it a strong contender in the hiking gear market. With a release set for the end of March 2025, this pack is worth keeping an eye on for those planning extended adventures.
