Zpacks Arc Haul 62L Review

Overview

The Zpacks Arc Haul 62L is a now-discontinued ultralight framed backpack aimed squarely at long-distance hikers and thru-hikers who need serious volume without abandoning the sub-1.5 lb weight class. Long days between resupplies demand a pack designed with ample space and durability, and the Arc Haul was built to be a workhorse from the Sierras to the Shenandoah. This pack has since been replaced by the Arc Haul Ultra, which uses a more durable Ultra material and adds a Lycra back panel for improved comfort. If you’re hunting a used market deal or comparing generations, read on — there’s a lot to like here, and a few things to watch out for.

Key Specs

Spec	Value
Weight	682 g (24.1 oz / 1 lb 8 oz)
Volume	62L (49L main, 2.5L × 2 side pockets, 8L front mesh pocket)
Fabric	4.85 oz/sqyd Gridstop
Frame Heights	Short 19”, Medium 21.5”, Tall 24”
Body Dimensions	8” × 12.5” × 30”
Load Capacity	30–35 lbs comfortable, 40 lbs max
Closure	Roll-top with Velcro
Status	Discontinued (replaced by Arc Haul Ultra)
Comparison	See how Arc Haul 62L Backpack compares to similar gear

Performance

The Arc Frame System

The defining feature of this pack — and the reason people keep buying it on the used market — is Zpacks’ patented Flexed Arc Frame. The system uses a trampoline-style mesh back panel suspended on an external frame consisting of three horizontal stays (top, middle, bottom) and two vertical stays made from a flexible carbon material. The hip belt attaches to the bottom horizontal stay and the shoulder straps to the top. The frame keeps the pack stiff so most weight rides on the hips rather than the shoulders. The frame pieces and mesh back panel can be easily removed or replaced. The curve creates airflow between your back and the pack, and you tune it by tensioning the mesh panel — Zpacks recommends about 2.5” of arch.

In practice, that ventilation gap is a real differentiator on hot, humid days. The Arc Haul keeps you cooler and works well in humid climates where sweat is a constant problem. That said, dialing in the arch isn’t totally intuitive. Getting the same arc in each side without introducing a twist in the back panel takes some practice. Watch Zpacks’ fit video before you hit the trail.

Carrying Comfort

Users with the right fit consistently report the pack as exceptionally comfortable, crediting the adjustable shoulder straps, load lifters, and the interchangeable padded belt with its waist-hugging twin-strap system.

The V-style hip belt is a particular highlight —

the “V style” webbing lets you cinch down the top and bottom edges of the belt independently, hugging your curves more securely than a single-adjustment belt.

One recurring caveat: if you overload the pack — as happens on long food carries — the top metal bar can jut into your back. At heavy loads (12+ kg), the bottom of the frame also becomes noticeable, though not acutely uncomfortable; an optional lumbar pad resolves this entirely. Think of 30 lbs as the real sweet spot, not a starting point.

Fit is not one-size-fits-all. Some users with narrower shoulders found the straps too wide and, after using the sternum strap to pull them in, experienced shoulder soreness over longer carry days. Zpacks does offer interchangeable strap options, so it’s worth a call to them before ordering if you have a narrower build.

Water Resistance

The roll-top closure keeps water out like a dry sack, and all seams and attachment points are taped, making the pack highly water resistant.

The Gridstop fabric is rated to 20,000 mmH₂O and is seam-taped throughout — tough, light, and very weather resistant.

Zpacks still recommends dry bags for critical items like your sleeping bag, which is reasonable belt-and-suspenders advice.

Organization

The pack is essentially one large 49L sack, two 2.5L side pockets, and an 8L front mesh pocket — totaling 62L. This configuration has become standard on many UL packs.

The side pockets fit 1 or 1.5L bottles and are positioned low on the pack, slanted forward for easy access without removing the pack.

There’s no internal organization to speak of — no hip belt pockets, no internal divider.

Hip belt and shoulder strap pouches are all add-on purchases, and the accessories add up quickly in both weight and cost.

Bear canister users will appreciate that all standard canisters, including the Bearikade Expedition and BearVault 500, fit in the upper half of the pack standing on end, with enough room to wrap a foam pad around the canister or stand a medium stuff sack beside it.

Durability

The Gridstop fabric itself holds up well. The crisscrossing nylon and HDPE threads give it excellent tear resistance, while the waterproof urethane coating and sealed seams inspire confidence in wet weather. An early Arc Haul purchased in 2017 reportedly looked and functioned like new after years of regular use.

The carbon stays are the weaker link. A common refrain in user reviews is that the Arc Haul is a super light, nice pack, but it is a little fragile. The pack layout is genuinely great, but at least one user reported a rod snapping mid-hike — with no replacement available in time for the next trip. QC on the stays has been inconsistent: some users received struts with rough cut ends or machined notches. Zpacks has generally replaced defective parts free of charge. Keep a spare set of stays if you’re mid-thru-hike.

Pros & Cons

Pros

• Excellent back ventilation via the Arc Frame — a genuine edge in hot or humid conditions
• Solid hip transfer for an ultralight pack; comfortable up to ~30 lbs
• Patented adjustable torso height works across a wide range of body types
• Interchangeable, removable hip belt is a thoughtful long-thru-hike feature
• Gridstop fabric is meaningfully tougher than DCF at a negligible weight penalty

• The Arc Haul’s Gridstop construction allows it to be one inch deeper in the main compartment than DCF alternatives, translating to about 7 extra liters of volume for only 85g more weight

• Bear-canister-compatible with room to spare
• Highly water resistant out of the box

Cons

• Discontinued — new stock unavailable; used market or Arc Haul Ultra only
• Carbon stays can break; no same-day replacement option on the trail
• Shoulder straps run wide and may not suit narrower builds without modifications
• No internal organization; hip belt pockets are costly add-ons
• Frame setup and fit-tuning requires time and the instructional video — not plug-and-play
• Overloading past ~30 lbs causes the top frame bar to dig into your back

• At loads above ~15 kg, the hip belt can twist horizontally, pushing the bottom horizontal stay into the lower back

Who Should Buy This

The Arc Haul 62L is the right call for ultralight-leaning thru-hikers who carry a genuinely light base weight — think sub-12 lbs — and need the volume for 5-6 day food carries in hot climates where pack ventilation really matters. It’s among the best ultralight packs for multi-day backpacking as long as you keep your base weight well within the recommended range. Because it’s discontinued, it’s primarily a used-market buy now. If you find a clean example and match the shoulder-width profile, it’s still a very capable pack. If you’re buying new, the Arc Haul Ultra is the obvious next step.

Verdict

The Arc Haul 62L earned its reputation as a thru-hiker staple: genuinely light, better-ventilated than most framed packs, and more adjustable than the ultralight category typically offers. The carbon stay fragility and the narrower-shoulder fit issue are real enough to factor into your decision, but neither is a dealbreaker for hikers who stay within the pack’s comfortable load range and keep a spare stay in their bounce box. On the used market at the right price, it’s still a strong 62L option — just know that its successor addresses several of the rough edges. 8/10.