Tortuga Travel Backpack Pro 40L Review
The fourth iteration of Tortuga’s flagship pack delivers expanded capacity while maintaining predecessor’s weight. Building on the Outbreaker‘s foundation, this stripped-down design prioritizes versatility over built-in organization.
Our Verdict
Pros
- Main fabric is recycled
- Very supportive hip belt and comfortable shoulder straps
- More spacious than its predecessor at the same weight
Cons
- Adjacent compartments can rob space from each other
- Main compartment’s inner flap zips, unintuitively, in the opposite direction
- Fewer organization options versus its predecessor
Technical Details
Disclaimer: We take the measurements of the bag provided by the manufacturer and compare them to the allowance listed on airline websites. This should be used as a guideline rather than a rule. Bags can change size as you pack them out, and every airline’s interpretation of compliance is different. Just because a bag is listed as carry-on compliant here doesn’t mean that the airline will interpret it that way.
Carry-on Compliance
View 111/145 Airlines
Like the Look
Polled on Instagram
- Capacity: 40l
- Weight (lb): 4.5 lb (2 kg)
- Denier: 200D Recycled polyester face fabric
- Denier: 70D Recycled ripstop polyester backing fabric
- Dimensions: 21.7 in x 13.8 in x 7.9 in (55.1 x 35.1 x 20.1 cm)
- Notable Materials: Recycled Polyester, Ripstop Polyester, DWR Coating, YKK Zippers, Woojin Hardware
- Manufacturing Country: Vietnam
- Laptop Compartment Size: 16"
- Warranty Information: Tortuga Common Decency Guarantee
Full Review
Our extensive testing revealed a refined travel pack that emphasizes efficient space utilization over complex organizational features – ideal for travelers who rely on packing cubes and pouches.
External Components
The Travel Gear Collective team extensively tested the pack’s new SHELL200 fabric – a notable departure from previous materials. After working with the 1680-denier ballistic nylon of early versions and X-Pac VX21 of the third generation, this innovative material caught our attention.
SHELL200’s three-layer construction mirrors X-Pac, featuring a 200-denier recycled polyester face, 45° recycled polyester cross-ply, and 70-denier recycled ripstop polyester backing. Our testing confirmed waterproof performance matching X-Pac VX21, but at reduced weight – the 40L maintains the same weight as its 35L predecessor.
The material exhibits a distinctive sheen compared to VX21 and ballistic nylon, with a crunchier texture that produces noticeable sound. During field testing, we observed excellent durability suitable for light outdoor excursions, thanks to polyester’s superior abrasion resistance. While our pre-production sample showed some loose threads, this typically resolves in final production units.
The pack features two padded handles – top and right side. Despite fewer grab points than competing travel backpacks, our testing found the minimal approach functional, though users frequently accessing bags in tight spaces may desire additional options.
YKK AquaGuard zippers protect the main compartments, demonstrating smooth operation unusual for weatherproof zippers. Our long-term testing confirmed consistent performance without the stiffness typically associated with AquaGuard designs.
The single water bottle pocket accommodates our 26-ounce YETI Rambler with a snug fit. The simple elastic design limits capacity – larger bottles like 32-ounce Hydro Flasks exceed its capabilities.
The harness system incorporates height-adjustable shoulder straps on hook-and-loop panels, similar to the Salkan Backpacker. Combined with load lifters, this system effectively customizes fit and minimizes sag. Despite relying on hook-and-loop attachment, the panel maintained stability throughout testing.
Premium padding matches the Outbreaker’s comfort level, with integrated keeper loops managing load lifter slack. The redesigned back panel features improved weight distribution and mesh ventilation for enhanced airflow.
The detachable hip belt equals the shoulder straps’ padding quality. We particularly appreciated the G-hook attachment system with hook-and-loop security – a significant improvement over traditional gatekeeper clips.
Fit Notes
Left: Eric Hergenreder, Height: 6’0″ (183 cm), Torso: 18.5″ (47 cm) | Right: Lauren Maternowski, Height: 5’6″ (168 cm), Torso: 16.5″ (42 cm)
Our testing across different body types confirmed the pack’s adaptability. The comprehensive harness system – combining load lifters, sternum strap, and adjustable panel – enabled precise fit customization. Despite the 40-liter capacity, the refined carrying system prevents overwhelming bulk.
The hip belt emerged as the standout feature in our testing. With a fully loaded pack, it effectively transfers weight from shoulders to hips, evidenced by visible gaps between shoulder straps and shoulders. The integrated hip belt pockets provide convenient storage for smartphones and small essentials, adding practical value beyond load distribution.
Inside The Backpack
The front features a three-quarter-length zippered stash pocket. Our testing revealed this multi-purpose compartment works best for larger items, though the left-side opening requires attention when accessing contents while standing.
For smaller items, we found the upper front pocket more practical. This shallower compartment includes a key clip and bright interior lining that enhanced visibility during our gear searches.
Behind the top pocket lies the admin compartment, offering the pack’s most detailed organization. The fold-down front panel provides full access, though we discovered that overpacking the front pockets can restrict this feature.
The admin section’s layout includes four card slots, two pen holders, and a mesh pocket on the left. A Kindle-sized tablet pocket sits behind these, with a wide, shallow zippered pocket below. The compartment’s depth accommodates larger items like the GOT BAG Shower Bag while maintaining accessibility.
The laptop compartment represents a design shift from its predecessor, featuring a horseshoe opening rather than full clamshell access. Our testing confirmed adequate functionality despite this change. The compartment includes a fleece-lined sleeve fitting a 16-inch MacBook Pro, substantial drop protection, and a tablet pocket we repurposed for a travel keyboard. A wide, shallow pocket effectively stores laptop peripherals.
Compared to the Outbreaker Travel Backpack 35L, the main compartment strips away built-in organization in favor of open space. This design shift benefits users of pouches and packing cubes, though previous Outbreaker users may miss the integrated organization.
A cover-side zippered flap provides additional storage, though its counter-intuitive zipper direction – running from edge to hinge rather than along the perimeter – required adjustment during testing. While this design prevents accidental spills, it conflicts with user expectations.
Our extended testing revealed some space management considerations. Adjacent compartments can impact each other’s capacity – notably, the laptop compartment’s top pocket and front stash pocket contents can intrude into the main space.
Usage Timeline
Initial Usage
Condition: Excellent
- Materials demonstrate durability
- Organization proves intuitive
- Adjustable harness system performs effectively
Condition: Excellent
- Pre-production unit shows minor thread issues
- Compartment space competition noted when fully packed
- Material maintains integrity
Author: The Travel Gear Collective Team
The Travel Gear Collective team combines expertise from gear designers, professional photographers, adventure guides, and sustainable travel specialists. Our rigorous testing protocols and real-world experience inform every review, ensuring practical insights for travelers worldwide.
Other Bags & Pouch Reviews
Table of Contents
Tortuga Travel Backpack Pro 40L Review
The fourth iteration of Tortuga’s flagship pack delivers expanded capacity while maintaining predecessor’s weight. Building on the Outbreaker‘s foundation, this stripped-down design prioritizes versatility over built-in organization.
Our Verdict
Pros
- Main fabric is recycled
- Very supportive hip belt and comfortable shoulder straps
- More spacious than its predecessor at the same weight
Cons
- Adjacent compartments can rob space from each other
- Main compartment’s inner flap zips, unintuitively, in the opposite direction
- Fewer organization options versus its predecessor
Technical Details
Disclaimer: We take the measurements of the bag provided by the manufacturer and compare them to the allowance listed on airline websites. This should be used as a guideline rather than a rule. Bags can change size as you pack them out, and every airline’s interpretation of compliance is different. Just because a bag is listed as carry-on compliant here doesn’t mean that the airline will interpret it that way.
Carry-on Compliance
View 111/145 Airlines
Like the Look
Polled on Instagram
- Capacity: 40l
- Weight (lb): 4.5 lb (2 kg)
- Denier: 200D Recycled polyester face fabric
- Denier: 70D Recycled ripstop polyester backing fabric
- Dimensions: 21.7 in x 13.8 in x 7.9 in (55.1 x 35.1 x 20.1 cm)
- Notable Materials: Recycled Polyester, Ripstop Polyester, DWR Coating, YKK Zippers, Woojin Hardware
- Manufacturing Country: Vietnam
- Laptop Compartment Size: 16"
- Warranty Information: Tortuga Common Decency Guarantee
Full Review
Our extensive testing revealed a refined travel pack that emphasizes efficient space utilization over complex organizational features – ideal for travelers who rely on packing cubes and pouches.
External Components
The Travel Gear Collective team extensively tested the pack’s new SHELL200 fabric – a notable departure from previous materials. After working with the 1680-denier ballistic nylon of early versions and X-Pac VX21 of the third generation, this innovative material caught our attention.
SHELL200’s three-layer construction mirrors X-Pac, featuring a 200-denier recycled polyester face, 45° recycled polyester cross-ply, and 70-denier recycled ripstop polyester backing. Our testing confirmed waterproof performance matching X-Pac VX21, but at reduced weight – the 40L maintains the same weight as its 35L predecessor.
The material exhibits a distinctive sheen compared to VX21 and ballistic nylon, with a crunchier texture that produces noticeable sound. During field testing, we observed excellent durability suitable for light outdoor excursions, thanks to polyester’s superior abrasion resistance. While our pre-production sample showed some loose threads, this typically resolves in final production units.
The pack features two padded handles – top and right side. Despite fewer grab points than competing travel backpacks, our testing found the minimal approach functional, though users frequently accessing bags in tight spaces may desire additional options.
YKK AquaGuard zippers protect the main compartments, demonstrating smooth operation unusual for weatherproof zippers. Our long-term testing confirmed consistent performance without the stiffness typically associated with AquaGuard designs.
The single water bottle pocket accommodates our 26-ounce YETI Rambler with a snug fit. The simple elastic design limits capacity – larger bottles like 32-ounce Hydro Flasks exceed its capabilities.
The harness system incorporates height-adjustable shoulder straps on hook-and-loop panels, similar to the Salkan Backpacker. Combined with load lifters, this system effectively customizes fit and minimizes sag. Despite relying on hook-and-loop attachment, the panel maintained stability throughout testing.
Premium padding matches the Outbreaker’s comfort level, with integrated keeper loops managing load lifter slack. The redesigned back panel features improved weight distribution and mesh ventilation for enhanced airflow.
The detachable hip belt equals the shoulder straps’ padding quality. We particularly appreciated the G-hook attachment system with hook-and-loop security – a significant improvement over traditional gatekeeper clips.
Fit Notes
Left: Eric Hergenreder, Height: 6’0″ (183 cm), Torso: 18.5″ (47 cm) | Right: Lauren Maternowski, Height: 5’6″ (168 cm), Torso: 16.5″ (42 cm)
Our testing across different body types confirmed the pack’s adaptability. The comprehensive harness system – combining load lifters, sternum strap, and adjustable panel – enabled precise fit customization. Despite the 40-liter capacity, the refined carrying system prevents overwhelming bulk.
The hip belt emerged as the standout feature in our testing. With a fully loaded pack, it effectively transfers weight from shoulders to hips, evidenced by visible gaps between shoulder straps and shoulders. The integrated hip belt pockets provide convenient storage for smartphones and small essentials, adding practical value beyond load distribution.
Inside The Backpack
The front features a three-quarter-length zippered stash pocket. Our testing revealed this multi-purpose compartment works best for larger items, though the left-side opening requires attention when accessing contents while standing.
For smaller items, we found the upper front pocket more practical. This shallower compartment includes a key clip and bright interior lining that enhanced visibility during our gear searches.
Behind the top pocket lies the admin compartment, offering the pack’s most detailed organization. The fold-down front panel provides full access, though we discovered that overpacking the front pockets can restrict this feature.
The admin section’s layout includes four card slots, two pen holders, and a mesh pocket on the left. A Kindle-sized tablet pocket sits behind these, with a wide, shallow zippered pocket below. The compartment’s depth accommodates larger items like the GOT BAG Shower Bag while maintaining accessibility.
The laptop compartment represents a design shift from its predecessor, featuring a horseshoe opening rather than full clamshell access. Our testing confirmed adequate functionality despite this change. The compartment includes a fleece-lined sleeve fitting a 16-inch MacBook Pro, substantial drop protection, and a tablet pocket we repurposed for a travel keyboard. A wide, shallow pocket effectively stores laptop peripherals.
Compared to the Outbreaker Travel Backpack 35L, the main compartment strips away built-in organization in favor of open space. This design shift benefits users of pouches and packing cubes, though previous Outbreaker users may miss the integrated organization.
A cover-side zippered flap provides additional storage, though its counter-intuitive zipper direction – running from edge to hinge rather than along the perimeter – required adjustment during testing. While this design prevents accidental spills, it conflicts with user expectations.
Our extended testing revealed some space management considerations. Adjacent compartments can impact each other’s capacity – notably, the laptop compartment’s top pocket and front stash pocket contents can intrude into the main space.
Usage Timeline
Initial Usage
Condition: Excellent
- Materials demonstrate durability
- Organization proves intuitive
- Adjustable harness system performs effectively
Condition: Excellent
- Pre-production unit shows minor thread issues
- Compartment space competition noted when fully packed
- Material maintains integrity
Author: The Travel Gear Collective Team
The Travel Gear Collective team combines expertise from gear designers, professional photographers, adventure guides, and sustainable travel specialists. Our rigorous testing protocols and real-world experience inform every review, ensuring practical insights for travelers worldwide.