We recently stumbled upon some creative bikepacking bags made from old USPS mailing envelopes, and they look to be holding up impressively well following their first overnighter. Find photos and a little background from designer Marcus Hamilton here…

Marcus Hamilton is an industrial designer in Kalamazoo, Michigan, and I recently came across one of his Instagram posts showcasing a set of unique handmade bikepacking bags that he made from upcycled USPS mailers. The project combined his interests creating things that incorporate unusual materials, graphics, and processes, and the results are pretty eye-catching. For now, the set includes a small handlebar roll and a partial frame bag. Both attach via Voile Straps and are backed by harder-wearing materials. Including straps, the handlebar bag and frame bag weigh in at 175 and 225 grams, respectively.

Marcus Hamilton, Upcycled USPS Mailer Bikepacking Bags
  • Marcus Hamilton, Upcycled USPS Mailer Bikepacking Bags
  • Marcus Hamilton, Upcycled USPS Mailer Bikepacking Bags
  • Marcus Hamilton, Upcycled USPS Mailer Bikepacking Bags

Here’s what Marcus had to say about the bags: “For this experiment, I thought it would be fun to utilize a handful of used USPS Tyvek envelopes that I had lying around and repurpose them into a set of functional bikepacking bags. The material is incredibly light. However, it’s prone to tearing. For longevity, I backed the interior panels with X-Pac VX21. Overall, they held up well on their first overnight trip. The all white Tyvek tends to absorb and hold onto stains more so than other bags. I think they’ll have a nice dirt patina overtime.”

  • Marcus Hamilton, Upcycled USPS Mailer Bikepacking Bags
  • Marcus Hamilton, Upcycled USPS Mailer Bikepacking Bags

Materials

  • Used USPS Tyvek Envelopes
  • X-Pac VX21
  • Cordura Ballistic Nylon
  • Cordura Nylon Webbing
  • YKK Aquaguard #5 Zipper

Interested in DIY bikepacking gear? Explore our #MYOBG tag to find all kinds of tutorials and inspiration for making your own gear.

Further Reading

Make sure to dig into these related articles for more info...

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