This thread is great, and I wish you the best of success. Since we're obsessing over the issue of loose straps (something I too HATE about much of the soft gear out there), can I just toss this in: "If the only tool you have is a hammer, everything will look like a nail." - Kaplan / Maslow I wonder if there is another means of fastening / cinching / binding that does not involve 1" nylon webbing and the extra length that has to be dealt with? Someone else mentioned lacing - that's an option. It works great in boots. Stuff in the laces and fold over the flap to cover them. The ideal of accordion pleats was also offered. And also a folding design. Are there other materials that might work. ... elastic? rubber? Maybe there's another approach that would work that you just aren't considering. Good luck.