Building my own Hawaiian Pack
The Hawaiian Pack is one of the simpler means of securing a tank to ones back and they were quite popular for a time with working divers or those who spent a lot of time getting in and out of boats. When used with a tank that allows for neutral buoyancy, it is easy to don and doff in or out of water and can even be hung on the gunnel of a skiff, yet it is also secure enough in the water for most OW diving.
I decided I wanted to try and make a Hawaiian Pack for myself and I have tinkered with this project on and off for about a year. Along the way, I have learned a good deal about backplate design and working with various materials.
Left: A Hawaiian Pack is part of a Combat Divers display at the Military Engineers Museum in Chilliwack BC.
My first plan was to make the Hawaiian Pack out of cheap materials so I could experiment and change things as I went along.
This was a good idea as I kept finding parts I wanted to change but from the beginning the backpack itself was completely functional.
Almost all of the design changes I made were either cosmetic or based upon moving the regulator closer to optimal double hose positioning.
Right: Design #1 with plywood backplate and common steel shoulder hoops.
Bending the hoops
Prototype #1 after a dive in the lake
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After getting the shoulder hoops bent and sized the way I wanted, I went on to make a final set out of brass.
For shoulder padding I decided to use leather for a unique vintage look. To protect the leather I heavily impregnated it with Beeswax by heating and reheating the hoops in the oven (on low) until the leather would no longer absorb the wax. I added two brass D rings to the shoulder pads when I was stitching them together.
I also made a tank band out of brass and changed the backplate design to allow the cans to sit lower. Unfortunately, the location of tank band, too high up on the tank neck and not the plywood, limited the position of regulator.
Left: Second prototype with brass and cutout for regulator cans
For shoulder padding I decided to use leather for a unique vintage look. To protect the leather I heavily impregnated it with Beeswax by heating and reheating the hoops in the oven (on low) until the leather would no longer absorb the wax. I added two brass D rings to the shoulder pads when I was stitching them together.
I also made a tank band out of brass and changed the backplate design to allow the cans to sit lower. Unfortunately, the location of tank band, too high up on the tank neck and not the plywood, limited the position of regulator.
Left: Second prototype with brass and cutout for regulator cans
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Having the shoulder hoops completed I went on to experiment with several incarnations of backplate with various cutouts for the regulator and the addition of two tank bands in different positions.
One design problem I tried to over come was the fact that the regulator was held off of my back by the thickness of the plywood. Not a major issue in itself but I wanted to try and make the Hawaiian Pack as double hose friendly as possible.
Right: Design #4 with a groove down the center to try to address the position problem
One design problem I tried to over come was the fact that the regulator was held off of my back by the thickness of the plywood. Not a major issue in itself but I wanted to try and make the Hawaiian Pack as double hose friendly as possible.
Right: Design #4 with a groove down the center to try to address the position problem
One day I was looking at the backpack hanging on my wall, trying to rethink the same old issue, when I had an epiphany. Why use plywood at all! I saw how I could simply use brass to accomplish what the plywood had been doing and with that, I had the final design completed.
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In 40 years, the patina should be perfect
While the bolts hold well enough they do loosen over time so I will try my hand at braising to join the brass sections together (but still keep the bolts in place).
From this point I still want to add a waist strap but am waiting until the right material presents itself. I envision either a WWI/WWII ammunition belt with leather pouches (which were some of the first DIY weight belts used by pioneering divers) or something similar that fits with the period look I'm going for.
I also plan to make a leather pouch that clips onto the D rings to hold a de-chromed brass double hose in the chest mount position with a first stage supplying air via the hookah port... but that is another project :)
Left: Hawaiian Pack and USD Mistral double hose regulator ready for adventure.
From this point I still want to add a waist strap but am waiting until the right material presents itself. I envision either a WWI/WWII ammunition belt with leather pouches (which were some of the first DIY weight belts used by pioneering divers) or something similar that fits with the period look I'm going for.
I also plan to make a leather pouch that clips onto the D rings to hold a de-chromed brass double hose in the chest mount position with a first stage supplying air via the hookah port... but that is another project :)
Left: Hawaiian Pack and USD Mistral double hose regulator ready for adventure.
