A quick update on the rucksack search. I have found a couple of shops that might be able to do the mod to an ALICE ruck I am looking for. Getting one created is much more difficult than I at first thought. There are plenty of places that will make one but they want you to place an order for a minimum number of units (typically 100 or more) up-front.
I am going to take the ruck I have and get it modified and then wear it for a while to see how it fits. It could be that modding it to make it modular just throws the weight off and I will be kicking myself in the ass for ruining a good ruck. We will see. I will be lucky to have the work done and the ruck back by mid-January I think.
If the mod works out and I like it I will think seriously about trying to raise the funds to have a first production run manufactured. It looks like unit cost for the first production run, what the army limited production, will be in the neighborhood of $75-$125 per excluding design costs. I am going to pursue this because I am just unsatisfied with the options out there for a good ruck that does not weigh a ton, is modular, but is not full of little pockets inside that generally just fill up with extraneous crap.
The bug bear when building a kit, GOTH or BOB, is striking a balance between what you need and what you want without making your ruck so heavy it becomes impractical. More is not always better when you are talking about something you have to hump around on your back for an indeterminate amount of time. That is the reason the rear areas of armies on the move has always been littered with discarded equipment. Soldiers keep what they need on campaign and nothing more. That should be the guide when setting up your kit as well.