563 – Pioneer Rucksack Pattern Tips

by Esi Hutchinson

I recently made the 563 – Pioneer Rucksack Pattern for myself, and I use it every day for work!  This is a popular sewing pattern because the bag is so practical, but it can be made from a wide variety of fabrics to get very different looks for every Rucksack. I love the one I made!  I wanted a waterproof bag to keep my papers and fabrics dry even when walking to work in the rain.  I used a Gray Ultrex waterproof fabric for the outer fabric and and for the lining.  I went with the more modern look and nylon webbing and black buckles.  We also have a 563 Pioneer Rucksack Kit you can purchase, which includes the all the webbing, buckles, zipper supplies, and padding for straps that you need to make this bag.

While this pattern is easy to sew, in this post I want to share a few tips and tricks that I figured out while making the Rucksack to make it even easier for you to make.

Webbing and Straps

I used 1" nylon webbing for my straps.  And I struggled a little with attaching straps in the correct places because my markings on the fabric were not clear. I highly recommend clearly marking the top, bottom, center line, and webbing placements on the bag fabric before you start sewing. My markings were light or unclear and this led to confusion about where the webbing needed to be attached. Which resulted in me sewing the webbing and straps to the wrong parts of the bag multiple times – a frustrating mistake that could easily be avoided with better preparation, like clear markings (and reading through the pattern).

I suggest using chalk or a fabric marker to make bold, clear marks.  Make sure that the marks can be wiped off or easily washed away. I think chalk is a great option, especially when working with dark waterproof fabrics, where marks can be hard to see. Chalk can be wiped off with a damp cloth.

Working with Waterproof Fabrics

While waterproof fabrics and laminated cottons are excellent for this project (and quite fun to work with!), you can also make this bag from denim or canvas if you prefer a more traditional look, though these won't offer the same weather protection. Again, I made this bag with Gray Ultrex waterproof fabric.

We have a post on sewing with waterproof breathable fabrics, and I find that needle choice is very important.  I recommend using a Microtex needle in size 70/10, as these are specifically designed for tightly woven and synthetic fabrics with coatings. The sharp point penetrates cleanly with little damage to the waterproof coating.

Seams: Consider using French seams or flat-fell seams for extra durability and waterproofing. But regular seams are fine too.

Seam Sealing:  Seam sealing prevents leaking at the seam lines where the fabric has been punctured by the needle.  For seam sealing this Rucksack, I used Coghlans Seam Seal.  This was my first experience with the process. This product fully cures in 24 hours. While I was impatient and continued sewing before it fully dried, I learned that patience pays off here. The ideal approach is to sew most of the project, apply seam sealer to all seams, and then wait a full day before continuing with any final assembly steps.

Seam sealing best practices:
•    Work in a well-ventilated area
•    Apply sealer to the inside of seams where possible
•    Use a small brush or applicator for even coverage
•    Pay special attention to stress points like strap attachment areas
•    Allow 24 hours for complete curing before using your item

If you have any further suggestions for seam sealing, let us know in the comments!

Durability Considerations

A good rucksack needs to withstand daily wear and tear. I haven't had any issues with my bag, just as the instructions called for, but if you want to reinforce key areas of your bag, consider the following:
•    Strap attachment points: These bear the most stress and can be reinforced with additional fabric or bartacking
•    Bottom corners: Consider adding protective patches or using heavier fabric here.
•    Zipper stress points: If using zippers, reinforce the ends with bartacks
•    Load-bearing seams: Double-stitch or use stronger seam types for areas that will carry weight

Other Considerations

If I were to make this bag again, I would make the webbing portion of the straps 10 inches longer on each side. There is not quite enough extra length for my preference, and having more adjustability would improve the fit and comfort.

I really love all the pockets in this rucksack, so I would definitely keep those. 

 Lots and lots of pockets which I love!