Choosing Replacement Buckles for an Outdoor Backpack

First consider what really happened to the piece of equipment and then how to best to repair it to make the job of checking the repairs prior to going out for a long hike, hunting, or work in the camp as easy as possible. Check the failed piece for any signs of wear or damage and then try to determine what the strap was being used for. That will help to determine what kind of buckle you will need to replace it with.

Start with the failure, not the catalog

Start by looking at the damage to your part. A cracked buckle side-release, a missing ladder-lock bar or torn strap require different repair solutions than a worn/broken buckle clip. Also, worn/broken webbing is probably also worn/broken in the rest of the strap and must be addressed as well. A new buckle clip may fix the problem of a cracked buckle side-release but if the webbing in the rest of the strap is also damaged then you have a larger problem that needs to be addressed.

Identify where the failure occurred. Is the failure in the buckle itself or in the webbing? If the webbing is cut, melted, abraded badly or is separating at the seams then you need a more far-reaching repair than just to replace a clip. Also ensure that you are not trying to sew through very worn material.

Just because you have a buckle for a pocket strap does not mean that you can use it to replace a sternum strap buckle, compression buckle, hip belt buckle or pack harness buckle. All of these serve different purposes and need to be replaced with the same type of buckle.

Match the hardware to the load path

The load path of a strap determines the direction in which forces travel when a pack is picked up, loaded, or is otherwise in use. Thus, major strap closures, such as the main straps and backpack harness components, should receive more consideration than that given to minor straps. Heavily laden packs subject their buckles to considerable stress, which is released upon each lowering and picking up of the pack, and upon contact with vegetation.

For heavier use load paths it is a good idea to try to match the original webbing width as closely as is possible. A clip meant for narrower material can try to pin a wider webbing strap while a buckle meant for wider straps could allow the strap to ride and thus get pulled. Measure the webbing itself, not the general term for the buckle such as medium or large.

Inspection of the mating pieces is also required to confirm that both the undamaged half and the replacement buckle (or buckle halves) are compatible. Side-release buckles typically consist of a male and female half, with specific shapes to engage in the straps. Inspection of the release buttons for proper engagement and smooth release without sticking is also required. Test the new buckle or buckle halves by hand to verify proper function prior to taking it on a trip.

Make sure your repair won't create any new snagging points. A repair with excess strap or a sharp edge could become problematic very quickly, especially if the repair is in an area where the strap could get caught in vegetation. Be sure to trim any excess strap and make sure the repaired area can be adjusted for different clothing layers and for heavy loads.

Know the common buckle types

The most common type of buckle found on straps, including sternum straps, compression straps, and general purpose closures, are side-release buckles. Side-release buckles are great because they can be opened and closed quickly even when the strap is passed through a slot. However, because they protrude from the strap, they can catch on things such as branches. Side-release buckles can also be damaged on one side which can cause problems with the closure as a whole.

Ladder-lock style adjusters work by friction to hold the webbing in place. Make sure to route the new ladder-lock through the exact same path as the original hardware. Pulling hard on the webbing will allow you to determine if it is going to grip properly or if it will slip through.

As well as evaluating a part for repair you need to establish the purpose of the strap in question. A small pocket closure strap carries a very different load to that of a sternum strap, compression strap or hip-belt straps. Make sure you are ordering the correct backpack buckle for the intended purpose.

Other parts such as sternum-strap clips, hook-and-loop keepers for additional straps, and special parts for hip-belt to chassis connections also exist. Their structural demands are lower but they affect wearer comfort so the new parts must sit correctly too.

Measure before cutting or sewing

Consider taking photos of the damaged harness before you start taking it apart. Make a rough sketch of the damaged strap from the pictures to make sure you don't end up re-making the whole strap. Note which side of the strap is outside the pack, how the webbing runs through the slots, and where the strap's adjuster range is.

Measure the width of the webbing and check the thickness of it. The slots in the buckle must be wide enough for the webbing and be of the right shape to prevent it from bunching up or coming loose. Make sure the new buckle is the same length as the old one. A buckle of slightly different shape can need more or less webbing to achieve the same end, when threaded.

Make sure you can open up the end of the strap to repair a buckle that has been sewn up as part of the strap closure. Make sure the stitchings are of a suitable nature for the strap and keep clear of any buckle parts that could move against it. Also make sure that the new stitching is not going to get caught against any edges of the buckle.

However, simple swaps, like replacing broken parts of worn straps with new ones, will require that you be able to thread new buckles on open ends of worn straps – note how such "fixed" ends of repaired webbing can eventually pull back and develop into raging snags later.

Install, inspect, and carry a spare

Finally, make sure to test the repair as you would use it. This should involve closing and opening the buckle repeatedly as well as fully extending and retracting the strap. Test it under tension as well as when simply hanging from a strap and apply force in the direction that the pack would normally pull. Look for signs of twisting or slipping of the webbing and for any signs of pinching or of the webbing coming into contact with any sharp edges.

Initial Testing. Run the pack through the normal carrying actions. Gradually increase the weight of the pack until it reaches the normal carrying weight. After each use, inspect the repair for signs of wear, ie: an increase in the lock's free play, webbing creep, seam lifting, etc. If any of these signs are noticed, then cease to use the repaired pack until further repairs can be made.

A spare buckle for your backpack's straps is more valuable for a remote trip than a large repair kit. Pack a spare buckle, and a short length of webbing that is identical to the original strap that was cut or destroyed. Be sure to pack out the failed plastic and the trimmed strap ends – small pieces of either can make nasty litter and even cause harm to wildlife on trails and in hunting areas.

Later, each season, and certainly after rough use, storage in warm locations and exposure to mud and salt, be sure to clean off any dirt from moving parts of the buckle. Allow any damp webbing to dry completely before using it. Look for any signs of stress or cracking and replace the part if in doubt. Ultimately good backpack repair is not about selecting the toughest looking part but about making an informed selection and testing the repair to ensure it will function as required.