Gregory Zulu 40 Review

Overview

The Gregory Zulu 40 sits in that awkward-but-useful space between “big daypack” and “light overnight pack.” It’s built around Gregory’s FreeFloat suspension — a perimeter wire frame paired with a trampoline-style mesh back panel — and aimed at hikers who want serious ventilation and load-carrying comfort without stepping up to a full-blown backpacking pack. If you’re doing long day hikes with camera gear, fastpacking overnights, or the occasional 2-3 night ultralight trip, this is the pack Gregory built for you.

Key Specs

Spec	Detail
Weight	1,330 g (2 lb 15 oz)
Volume	40 L
Max recommended load	16 kg (35 lb)
Packed dimensions	61 x 31.1 x 27.9 cm
Frame type	Perimeter alloy wire + fiberglass anti-barreling cross-stay
Torso adjustment	Yes, ~3.5” of range
Hydration compatible	Yes (SpeedClip hanger, sleeve fits Gregory 3D Hydro reservoir)
Rain cover	Included
Hip belt	FreeFloat 3D “comfort cradle,” dual zippered pockets

Performance

Carry comfort. This is where the Zulu 40 earns its keep. The FreeFloat suspension — a spring-wire X-frame connected to a yoke that pulls tension into the frame as the load increases — is designed so the shoulder straps connect to a yoke that pulls up on the wire frame above the crossover point that forms the “X,” forcing tension to increase in the frame as loads bear down on the shoulder harness. In practice, that translates to a pack that stays stable well beyond typical daypack loads. One reviewer running camera gear plus full hiking kit reported using it as a day pack to haul around camera gear in addition to all the usual hiking gear, typically carrying 30 to 35 pounds, and noted the pack straps and waist belt are really comfortable and easily adjusted. Gear Institute’s testing backs this up: the Gregory Zulu 40 is a very stable pack, even with heavier loads approaching 35 pounds, with the rigidity of the suspension system combined with spot-on ergonomics allowing a comfortable carry with heavier gear.

Ventilation. The mesh back panel is genuinely one of the better-ventilated setups I’ve come across in this category — Gregory’s whole pitch here is airflow, and it delivers. The ventilation system keeps air moving over much of the back, which matters a lot on the kind of long, sweaty summer days this pack is aimed at.

Trade-offs of that stiff frame. The same rigidity that makes it stable under load also makes it a poor choice for anything technical. Mobility is hampered by the torsional stiffness of the suspension system, making this pack better suited to trails, not alpine scrambles. If your trips involve scrambling, off-trail bushwhacking, or anything requiring a pack that moves with your body through awkward positions, look elsewhere.

Organization quirks. Access is via a drawstring top plus a convenient inverted-U zippered front opening, which is handy for digging into the main compartment without unpacking from the top. But there’s a real design flaw here: the outside stretch pocket is nice, but being attached to the front zippered access panel, it can dump pocket contents when the zippered panel is opened. I’d treat that front pocket as a spot for things you don’t mind occasionally chasing across a parking lot. The side stretch pockets have a similar annoyance — they’re not usable for water bottles or other items you want to access without taking the pack off, because compression straps cross them, though they work fine for something you’re not grabbing on the move, like a small stove.

Storage layout. Beyond the main compartment, you get a capacious top brain pocket that’s versatile, with a flat zippered pocket on the underside for keys, wallet, or passport. That’s about it for organized storage, though — the top/brain pocket is where most small stuff has to go, with the raincover pocket and two tiny hip belt pockets being the only other zippered storage. Don’t expect a pack covered in organizer pockets; Gregory kept this one relatively simple.

Fit range. Torso adjustment is a real strength. One 6-foot user with a 20-inch torso found the Medium (40L) fit nicely, carrying 15 lbs stably and comfortably, which lines up with Gregory’s claim of roughly 3.5 inches of adjustment range — enough to dial in a genuinely custom fit rather than picking between two rigid size options.

No bottom sleeping bag straps. Worth flagging if you’re using this for overnights: there are no bottom straps for carrying a pad or sleeping bag there, so you’ll need to stash those items inside or lash them elsewhere.

Pros & Cons

Pros

• Stable, comfortable carry even at 30-35 lb loads, well above typical “daypack” territory
• Excellent back-panel ventilation thanks to the trampoline mesh design
• Generous torso adjustment range makes for a genuinely dialed-in fit
• U-zip front panel gives full access to the main compartment without top-loading only
• Rain cover included — no extra purchase needed
• Versatile enough to flex between long day hikes and 2-3 night ultralight trips

Cons

• Torsionally stiff frame makes it clumsy for scrambling or technical off-trail terrain
• Front stretch pocket can spill contents when the U-zip panel is opened
• Side pockets are compression-strapped, so they’re not great for on-the-go bottle access
• Minimal organized storage beyond the brain pocket — no dedicated pad/bag straps at the bottom
• At 1,330 g, it’s not a true ultralight pack; there are lighter 40L options if grams are your top priority

Who Should Buy This

The Zulu 40 makes the most sense for hikers who want one pack to cover long, sweaty day hikes and occasional light overnights — think fastpacking, hut-to-hut trips, or hostel-hopping trips abroad where a full 60L backpacking pack would be overkill. It’s also a solid choice if you carry heavier daytime loads (camera gear, extra layers, a full hydration setup) and want a suspension system that won’t collapse under 25-30+ pounds. Alpine scramblers and anyone prioritizing gram-counting ultralight builds should look at more flexible, lighter-frame packs instead.

Verdict

The Gregory Zulu 40 delivers real carrying comfort and ventilation at loads that would make most daypacks buckle, backed by a torso-adjustable fit that’s hard to beat in this category. It’s held back by a stiff frame that doesn’t love technical terrain and a few storage-pocket quirks that feel like oversights rather than dealbreakers. For trail-based day trips and light overnights, I’d rate it a 7.5/10 — comfortable and versatile, just not the pack to bring if your route gets hands-on.