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Logan WattsBy Logan Watts
Founding Editor & Routes Director
2,167 Posts
In a unique challenge to prove that adventure doesn’t have to break the bank, we embarked on a Budget Bikepacking Build-Off. The mission? To create a fully functional bikepacking setup for under $500. For my entry, I chose a black chrome 1988 Schwinn High Sierra. This vintage gem became the foundation for a project that involved DIY racks and bags, culminating in a complete kit, even featuring a self-made camp kitchen and a DIY spork. Explore the details of this sub-$500 kit, complete with a full gallery of photos from its inaugural overnight test run.
PUBLISHED Jan 14, 2025
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Budget Bikepacking Build-Off Rules: 1. Keep the total cost under $500 for the bike, bags, and camping gear. 2. No freebies or using parts from your existing stash. 3. No professional discounts – pay full price for everything, new or used. 4. Prioritize buying locally when possible. 5. Test the completed setup with a real bikepacking overnight trip.
The concept of a Budget Bikepacking Build-Off might seem paradoxical to some. After all, many of us already possess bikes and a collection of bikepacking gear. Participating means acquiring more equipment, seemingly just for content creation. However, the underlying purpose is much deeper. It’s about demonstrating possibility and inspiring those starting from zero. It’s about showing viable options when budget constraints are the primary barrier to entry into multi-day bike adventures. We’ve long championed the philosophy of using what you have. Seeing this principle in action, learning to achieve bikepacking on a limited budget, directly challenges the notion that one must invest in the latest, most expensive bikes, bags, and gear to experience bikepacking. This project aims to democratize adventure and prove that the spirit of bikepacking is about resourcefulness and ingenuity, not just high-end equipment.
Budget Bikepacking Build-Off Logan WattsThe Build-Off process itself was profoundly rewarding. It forced a shift in perspective, demanding creative problem-solving within budgetary limits. It served as a stark reminder of the escalating costs of goods and materials, urging us to reconsider consumerism and minimize waste. Staying under the $500 mark while creating something reliable, aesthetically pleasing, and genuinely interesting proved to be a significant challenge.
This challenge was precisely the intended direction. Initially, I even proposed naming the series Concours de Rummage, drawing inspiration from the high-end Concours de Machines builders competition. The core idea was to encourage a resourceful, DIY approach, utilizing reclaimed materials and ingenious solutions to common bikepacking needs. However, recognizing that DIY is just one approach within a spectrum of budget-friendly solutions, we broadened the scope to welcome diverse interpretations of a capable, low-cost touring setup. The variety in approaches and motivations ultimately enriched the Build-Off, making it even more compelling.
The Quest for the Right Steed: Finding a Vintage Schwinn
The most daunting phase of this Build-Off was finding the right bike to start with. Living in Brevard, North Carolina, a smaller town, the used bike market, whether through thrift stores or online marketplaces like Facebook Marketplace, is relatively limited. Furthermore, vintage mountain bikes from the 80s and 90s often come in smaller frame sizes. Locating an XL or XXL frame proved particularly difficult. Just as I identified a promising candidate, Hurricane Helene intervened.
In the week leading up to the storm, a 22″ 1988 Schwinn High Sierra appeared on Marketplace. I contacted the seller immediately, arranging a meeting for that Thursday just across the state border in Tennessee. Unfortunately, unprecedented rainfall and the impending hurricane made travel impossible. By Friday, as Helene made landfall, communication with the seller, and indeed the outside world, ceased entirely. Internet and phone service were down for a week, the region suffered significant damage, and road access between western North Carolina and Tennessee remained closed for nearly a month. Thankfully, the seller was incredibly understanding, holding onto the Schwinn for me until I could finally make the trip almost a month later. It was worth the wait. This 22″ Black Chrome beauty, a true Schwinn classic, was in excellent condition for its age and perfectly embodied the history of off-road cycling. It was, in my view, the ideal canvas for a Budget Build-Off bike.
1988 Schwinn High Sierra, Budget Bikepacking Build-Off Logan Watts
The 1988 Schwinn High Sierra: A Bikepacking Foundation
The name “Sierra” has a rich and varied history within the Schwinn lineage, initially appearing in 1963 to denote a road bike model. However, in 1983, Sierra was reborn as the flagship model in Schwinn’s burgeoning All-Terrain Bike (ATB) lineup. By 1984, both the Sierra and the newly introduced High Sierra were officially categorized as “mountain bikes,” becoming Schwinn’s premier off-road offerings, with the High Sierra positioned at the top. Schwinn shifted back to the ATB designation in 1985 with the launch of the Cimarron as their premium off-road bike. Despite this repositioning, the High Sierra remained a consistent model in Schwinn’s catalog from 1984 to around 1996, typically occupying the second or third tier within their range.
1988 Schwinn High Sierra, Budget Bikepacking Build-Off Logan Watts
The 1988 High Sierra model, while positioned third in Schwinn’s 1988 ATB lineup after the Project KOM and Cimmaron, arguably stood out with its striking Black Chrome fillet-brazed chrome-moly frame. This frame boasted triple-butted main tubes and ovalized seat tube and fork blades, showcasing quality construction. The componentry included SunTour XCD-6000 derailleurs and Accushift shifters, a Dia-Compe 983E front cantilever brake, Dia-Compe 284II mini-power levers, and the distinctive Advantage 990 under-chainstay rear cantilever brake. This Schwinn bike was a testament to late 80s mountain bike design.
1988 Schwinn High Sierra, Budget Bikepacking Build-Off Logan Watts
1988 Schwinn High Sierra, Budget Bikepacking Build-Off Logan Watts
Fortunately, this particular 1988 Schwinn High Sierra was in good working order when acquired for $150. Aside from the slick tires, it retained its original components, including the narrow 24” handlebars, Schwinn Team Issue stem, and Weinmann 522X rims. While replacement parts weren’t strictly necessary, knobbier tires were added for improved aesthetics and durability, essential for off-road bikepacking. The key to a budget build is careful sourcing of used bikes. The strategy was to find bikes priced either under $100 requiring some upgrades, or in the $150-$250 range needing minimal work, avoiding budget blowouts on replacement parts.
DIY Racks and Bags: Embracing the Make-Do Ethos
Even before the Schwinn was in hand, ideas for DIY bags and racks were forming. Having favored rack-top bag setups in recent bikepacking trips, a rear rack was a priority. Utilizing an OEM rack strut kit and reclaimed hardwood from workshop construction, a custom rear rack was fabricated. To reduce weight and for visual symmetry, a matching front basket carrier was also built. A detailed tutorial on these rack builds is forthcoming, but the images offer a preview.
DIY Pants Leg Stuff Sack Rack Bag
Budget Bikepacking Build-Off Logan Watts
Budget Bikepacking Build-Off Logan Watts
For the bags, a $5 pair of size 44 blue jeans from a local thrift store was repurposed. The vision was a waxed jean-leg stuff sack for the rack-top bag, another DIY tutorial in progress. The remaining denim provided material for a Wald 137 basket bag, a frame bag, and a tool roll, detailed further below. Otter Wax was used to treat the denim, providing a water-resistant and aesthetically pleasing finish.
The frame bag design involved some deliberation, considering both half-frame and wedge shapes. The wedge design was chosen, constructed using repurposed Cordura, straps, and a zipper salvaged from an old Kona Sutra frame bag. While not everyone has access to such materials, old backpacks can serve as a source. The blue jeans, including a pocket repurposed as a knife sheath, were combined with leftover X-Pac for the side panels.
1988 Schwinn High Sierra, Budget Bikepacking Build-Off Logan Watts
Budget Camping Gear: Smart Choices for Overnight Adventures
Staying within the budget became more challenging with camping gear, typically the heaviest and most expensive components of a bikepacking setup. While used inflatable sleeping pads needing repair were available on Facebook Marketplace for $20-$30, a used Nemo Tensor was sourced for $70.75 to ensure reliability and match an existing pad.
Budget Bikepacking Build-Off Logan WattsAfter monitoring Marketplace for used sleeping bags, the North Face Cat’s Meow emerged as a common and affordable option. Despite its bulkiness, a 20° model was chosen for colder camping conditions, staying within a $50 budget. A DIY compression sack was ingeniously created from a polyethylene bag (likely from suspension fork packaging) and a nylon belt, effectively reducing the sleeping bag’s size for basket bag storage.
Beyond the pad, sleeping bag, and a Tyvek groundsheet, a borrowed DIY tarp completed the sleep system. Aluminum bar scraps were repurposed into lightweight, sturdy tent stakes, organized with a rubber band cut from an old inner tube.
DIY Camp Kitchen: Frugal Feasting on the Trail
Perhaps the most resourceful element of the kit was the $4.50 DIY camp kitchen. While some team members opted for no-cook meals to save money, assembling a functional kitchen was a priority.
Budget Bikepacking Build-Off Logan Watts
Budget Bikepacking Build-Off Logan Watts
Thrift store finds comprised the core components: a $1 enamel camp mug, a $2 pot with lid, and a $0.50 spoon, modified into a spork. The pot lid was replaced with a trimmed piece of wood for a lower profile within the frame bag. A standard DIY can stove and a windscreen/pot stand made from repurposed cans completed the kitchen. While the windscreen/pot stand was somewhat flimsy, the kitchen proved effective, especially for morning coffee.
Budget Bikepacking Build-Off Logan Watts
Budget Breakdown: The Numbers Behind the Build
The budget breakdown details the costs associated with each component. Notably, many bag-making materials were on hand from previous projects, including X-Pac scraps, wax, webbing, and buckles. While these weren’t factored against the budget as leftover materials, a researched value was assigned for transparency.
Bike
- $150 – 1988 Schwinn High Sierra (Facebook Marketplace)
- $91.55 – Vee Crown Gem Tires (Walmart)
Racks
- $35 – Wald Half Basket
- $34 – 2 x Rack Rear Strut Kit
- $0 – Reclaimed wood
- $0 – Found steel bar
- $16 – 2x Voile Straps
Bags
- $5 – Jeans (Goodwill)
- $13 – 1/2 yard X-Pac (Ripstop by the Roll)
- $10 – Miscellaneous scraps
- $0 – Repurposed materials from junked pack
- $0 – Repurposed political sign
- $20 – Otter Wax
Camping
- $0 – Borrowed tarp*
- $50 – The North Face Cat’s Meow 20° sleeping bag (Facebook Marketplace)
- $70.75 – Nemo Tensor Insulated sleeping pad (Marketplace)
- $0 – Tyvek sheet (reclaimed)
Camp Kitchen
- $1 – Denatured alcohol
- $1 – Mug (thrift store)
- $0.50 – Spoon (thrift store)
- $2 – Pot/lid (thrift store)
- $0 – Can Stove
—————————————— $499.80
Beyond the Budget: Essential Upgrades for Extended Trips
The build successfully met the sub-$500 challenge rules. However, to create a truly comprehensive bikepacking kit suitable for extended multi-week tours, certain upgrades would be necessary. These weren’t included in the budget build as they weren’t essential for the initial challenge and would have exceeded the $500 limit.
1988 Schwinn High Sierra, Budget Bikepacking Build-Off Logan WattsFirstly, wider handlebars would significantly improve ride comfort and control. The stock 610mm bars are too narrow for modern preferences. The 740mm Steve Potts Camper bars or the Magic Mothbar would be suitable upgrades, although handlebar options with a 25.4mm clamp diameter are limited.
1988 Schwinn High Sierra, Budget Bikepacking Build-Off Logan WattsWhile not mandatory for the Build-Off, a tool kit is essential for any bikepacking trip. A used tool kit was assembled as a comprehensive budget option. A simple tool roll made from leftover jean pocket fabric houses the tools.
Other desirable upgrades include a custom-made tarp, a Hite Rite (or dropper post), and tubeless tire setup—a personal preference for modern bikepacking.
Upgrades ($134-154)
- $44 – Hite Rite
- $90 to $110 – Steve Potts Camper or Magic Mothbar
Tubeless Setup ($20)
- $11 – Tubeless Schrader Valves
- $9 – Sealant
Camping ($80)
- *$80 – Estimated material cost for a DIY tarp (borrowed for the challenge)
Tools ($55)
- $26 – Crank Bros M19 multi-tool
- $10 – Leatherman tool
- $10 – Blackburn Pump
- $4 – Tire Lever
- $3 – Tubeless plugs
- $2 – Plugger
—————————————— $289 to $309
Including these upgrades, a more comprehensive multi-month dirt touring setup would total approximately $788 to $808. This remains a remarkably affordable price for a capable, all-inclusive bikepacking setup. The project highlights the accessibility of bikepacking, even with limited resources. While access to tools, materials, and sewing equipment is acknowledged as a privilege, the core principle of creative resourcefulness remains universally applicable. This build and process aim to inspire others to think outside the box when assembling their own bikepacking rigs. Despite the focus on gear in bikepacking culture, new equipment isn’t a prerequisite for adventure. Repurposed materials and ingenuity can create reliable, personalized setups ready for the open road.
Thank you for reading. Questions about the build are welcome in the comments below. Stay tuned for tutorials on the DIY racks and blue jean rack bag next week, followed by the basket bag tutorial the week after. More Budget Build-Off bike features are coming soon!
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