Ready for the Red Pill? Zpacks Arc Haul Ultra 60L Review – One of the Best Backpacks on the Market

Down the Rabbit Hole of Ultralight Backpacking: A Catalyst for Change

When I reflect on my transition into ultralight backpacking, the single piece of gear that influenced me the most was the Zpacks Arc Haul Ultra 60L pack. Choosing this backpack was like taking the red pill in The Matrix—once I embraced it, there was no turning back. The Arc Haul Ultra didn’t just lighten my load; it compelled me to rethink and scrutinize every item on my backpacking checklist.

Before adopting this pack, I was guilty of overpacking, often carrying unnecessary items “just in case.” My backpacking philosophy had been shaped by my involvement with the Boy Scouts of America, along with a particularly bad backpacking experience in my youth. The infamous Gabrielino trip, where we were caught overnight in a terrible rainstorm without proper gear, taught me the value of being prepared. This experience also caused me, over time, to swing the pendulum in the other direction—overpacking and lugging around excess weight.

The Arc Haul’s ultralight design and limited carrying capacity—along with my back surgery—forced me to evaluate the true necessity of each piece of gear. I began prioritizing functionality and weight, shedding ounces (even grams) wherever possible. This mindful approach not only reduced my overall pack weight but also transformed my entire hiking experience.

Weighing a mere 20.9 ounces depending on the configuration, this ultralight backpack offers a feature that many others in its weight class do not—a metal frame. Made from Ultra 100X fabric, the Arc Haul is as water-resistant as Dyneema but may be more abrasion-resistant due to its woven ripstop grid pattern. The pack’s hip belt and shoulder straps provide a comfortable carry, as long as you stay within its recommended weight limits.

Why it's great:

Limitations:

Why It’s Great

Ultralight Unicorn: Frame and 40# Capacity

This particular ultralight backpack is quite unique because it is the only backpack of this weight (~20oz) that has a frame and a 40 pound carrying capacity. Other frame packs in this class weigh at least 50% more and carry 5 pounds less. Truly an amazing feat Zpacks has accomplished!

Comfort

The Arc Hauls’ ultralight Curved Carbon Fiber Air Stays feature an arced design that improves ventilation (no sweaty backs—or less sweaty in my case) and enhances weight distribution. The padded shoulder straps provide a comfortable fit, and the hip belt efficiently distributes weight. Its 4-point adjustable front buckle allows for a more customized fit, making the load feel balanced and secure.

Durable

The Ultra 100X fabric, recently upgraded from Ultra 100, makes this pack even more durable with its woven ripstop grid design, offering enhanced resistance to UV damage and fading. However, like all ultralight backpacking gear, it’s essential to treat your backpack with care both on the trail and to clean it after trips.

High Capacity 60L

I’ve been able to fit my gear for both solo and group trips into this bag. A surprising aspect of this pack is how much you can fit into the elastic mesh pocket on the back—it feels like more than its stated 8L capacity. When needed, I’ve supplemented the main storage by carrying bulky clothing items (like a jacket) in a water-resistant dry sack attached to the two cinchable straps at the bottom of the pack. (47L main cargo tube, 8L back pocket, and 2.5L for each side pocket).

Water Resistant

Ultra 100X fabric is highly water-resistant, rated to handle more than 20,000 mm of water pressure. This means it can withstand heavy rain or snow without letting water through. A hydrostatic head of >20,000 mmH2O essentially means it would take the pressure of a 20-meter column of water stacked on top of the fabric to cause it to leak—that’s the equivalent to the height of two Olympic-sized 10-meter diving platforms’ worth of water stacked on top of each other. That’s a lot of water resistance. However, as I always say, nothing is truly waterproof except a rubber slicker. Everything, when exposed to rain heavy enough and long enough, will eventually wet out (soak through). I want to emphasize this because “waterproofness” is a commonly misunderstood concept among beginning backpackers.

Customizable

The Arc Haul Ultra is completely customizable to fit each hiker’s individuality, with the typical adjustments like torso height, belt length, and designs tailored to fit either a man’s or a woman’s body type. Optional add-ons are available to suit your hiking style. Personally, I have the water bottle sleeve (0.56oz), Ice Axe/Trekking pole loops on both sides of the pack (0.11oz), and a water bottle clip (no longer sold) for carrying an additional bottle with electrolytes, which came in very handy on Whitney.

Limitations

40-Pound Max Weight Capacity

This is a strict limit for both comfort and durability when it comes to ultralight materials, ensuring that your gear performs at its best without compromising structural integrity or long-term wear. Trust me, I’ve tested this limit firsthand and learned exactly why it’s so important.

Overloading Can Cause Discomfort and Wear

This bears repeating since it’s such a common occurrence in backpacking. Adding “just one more thing” — 8oz here and a pound there — and suddenly you’re at 45-50 pounds (don’t ask me how I know this). The strict weight limit on this piece of ultralight gear must be respected. This is in stark contrast to other great backpacks I own, like the Osprey Atmos, whose AntiGravity suspension system can carry far more weight comfortably but weighs nearly 5 pounds itself.

Minimalist Design Has Its Limits

Although I absolutely love my Zpacks Arc Haul Ultra, I realize not everyone is ready to go down the ultralight rabbit hole, and that’s perfectly fine. As I’ve mentioned before, I own many packs that work well for different situations and types of trips.

Overloading can take the "arc" out of Arc Haul

This pack’s uniqueness as one of the only ultralight “frame” packs of its weight does come with limitations. The curved carbon fiber air stays, combined with a Lycra “trampoline” back panel, prevent most of the pack from touching your back, maximizing airflow to reduce moisture and minimize rubbing while hiking. However, overstuffing the pack can compromise these minimalist frame stays to some extent. While this isn’t a deal breaker—since you can adjust the trampoline back and straps—it’s something to be mindful of nonetheless.

Possible Creaks and Squeaks

While this backpack has very few non-obvious limitations, there are a couple of minor annoyances. The minimalist straps and buckles can occasionally creak and squeak. It’s not a dealbreaker, but something you should be aware of. Ultimately, there’s no such thing as a free lunch (unless you’re a bear at Whitney Portal campground, where there are plenty of free lunch bags—aka backpacks. Source: see any Whitney forum).

In the Field

This may be the single best piece of ultralight backpacking gear I own

When I look back on the trips and summits I’ve attempted, my backpack always stands out as the piece of gear that makes or breaks a trip. It shuttles everything you own to survive in sometimes unfavorable conditions in the wilderness.

I’ve used this pack on nearly all of my backpacking trips and tested it on one mountaineering trip. I worked like a charm on my 2 day solo backpacking trip to Mount Whitney Trip where its versatility and customizability shined though. In addition to carrying all my gear to Trail Camp, which is where you camp just below the final summit push, it can be used as a great summit pack. I was able to cinch the pack to make it smaller both width wise as well as the roll topdown and I didn’t feel like I had any “forced carry” weight. The water bottle sleeve and water bottle clip accessories allowed me to not remove my pack, and actually continue walking, to drink water and electrolytes which is essential to stave off altitude sickness and dehydration on a 16 mile day like the summit day on Whitney.

I’ve also endured the limitations of the carrying capacity on a mid summer trip in Yosemite. On a 4 day trip up Yosemite Falls on the way to Eagle Peak and El Capitan, one member of the group began to develop some signs of heat sickness. After, cooling him down and allowing him to recover, I carried the majority of his gear up the last half of the Yosemite Falls trail (which is exposed to the sun and has relentless stone steps to the top. Probably well over 50 pounds my packs hip belt strap bit into my right hip bone. I ended up improvising additional padding using my head buff and was ok after that.

Finally, I pushed this pack to it’s volumetric limits on a recent attempt of Mount Shasta. Equipped, with ice axe, crampons, helmet, trekking poles, and 4 season tent I maxed out the volume this pack can handle. Although, it functioned admirably, I may opt for a bag designed to take the weight and volume typical of mountaineering trips.

Independent Designs from an Independent Outfitter

Though Zpacks has grown larger than many typical cottage companies, they remain proudly independent, operating out of a single factory in West Melbourne, Florida. Despite their growth, they continue to set the gold standard in the ultralight backpacking world, particularly with their high-quality tents and backpacks. Their gear is crafted with precision and attention to detail, earning them a loyal following among serious backpackers seeking top-tier performance at the lightest possible weight.

In addition to tents and backpacks, Zpacks also offers other high-quality gear, such as quilts and apparel, all designed with the same commitment to ultralight performance. I personally own their Arc Haul Ultra 60L backpack (19.6oz Ultra 100, pre-100X version), Vertices Rain Pants (a mere 3 ounces), several dry bags (0.5 ounces each), and a few of their baseball caps (can you tell which one I bring on EVERY trip?).

One of my favorite pieces of Zpacks gear, which never leaves my backpacking checklist, is perhaps the most versatile and inexpensive: the Zpacks foam sit pad. Weighing just 1 ounce and priced at only $9.95, it’s a must-have for any minimalist setup. I use it as a sit pad, a torso insulator as part of my sleep system on colder nights, a kneeling pad when accessing or setting up my tent, and as an insulator and cushion for my Helinox Chair Zero (1 lb).

Conclusion: A Game-Changer for Ultralight Backpacking

The Zpacks Arc Haul Ultra 60L wasn’t just a piece of backpacking gear—it was the catalyst that shifted my fundamental axiom of what was possible for me in the world of backpacking. Before adopting ultralight principles, I carried the weight of past experiences and over-preparation, believing that more gear meant more security (which it does provide, at a cost). But just like Neo’s journey in The Matrix, where he redefined his reality, this pack forced me to rethink everything I thought I knew. It wasn’t just about reducing weight; it was about embracing a new philosophy—one that prioritized efficiency, mindfulness, and the realization that I didn’t need to carry more to achieve more.

Although I will never dodge bullets or fly like Neo, ultralight backpacking gave me something just as powerful: the ability to continue backpacking after back surgery. For me, that’s the same thing. This pack allowed me to re-enter the wilderness with newfound freedom, no longer burdened by unnecessary weight or limitations. It transformed not just my approach to backpacking but my belief in what I could achieve on the trail. In the end, the Zpacks Arc Haul Ultra 60L didn’t just lighten my load—it expanded my horizons and maybe, just maybe, helped me see one more summit.

Bottom Line tl;dr

Why you might want to think twice

The minimalist design isn’t for everyone. If you’re not ready to “go down the rabbit hole” of ultralight backpacking, the Arc Haul Ultra may feel restrictive. Its 40-pound weight limit is firm, and overpacking will lead to discomfort. It does have some minor creaks and squeaks that I don’t even notice anymore, but they were more apparent in the beginning. Plus, it’s not the most budget-friendly option. If you need extra features like separate compartments (such as a “brain” or easy-access top compartment) or bottom zippered access, you may prefer a more traditional pack made from more durable materials.

Why you’ll love it

At just around 21 ounces, combined with a metal frame and a 40-pound carrying capacity, this pack is a game-changer. It forces you to pare down your backpacking gear to the essentials, lightening your load while maintaining comfort and functionality. It’s durable, highly water-resistant, and customizable to fit individual needs—whether you’re on a long-distance thru-hike or a quick summit push, it just works.