Think bags for biking are expensive? This bag maker explains what goes into making one. - Singletracks Mountain Bike News

Wes Holland is the owner of Bullmoose Softgoods where he designs and produces one-of-a-kind bags for cycling and adventuring. Bullmoose is based in Summerville, Massachusetts and currently offers handlebar and frame bags plus hip packs and accessories.

Check out Wes’s work at bullmoosesoftgoods.com.

An auto-edited summary of our conversation is provided below. For the full details you’ll need to listen to the entire podcast.

Jeff Barber [0:00]Hey everybody, welcome to the Singletracks podcast. My name is Jeff, and today my guest is Wes Holland. Wes is the owner of Bull Moose Soft Goods, where he designs and produces one-of-a-kind bags for cycling and adventuring. Bull Moose is based in Somerville, Massachusetts, and currently offers handlebar and frame bags, plus hip packs and accessories. Thanks for joining me, Wes.

Wes Holland [0:25]Thanks, Jeff, for having me.

Jeff Barber [0:27]So what came first for you? Was it bikes or bags?

Wes Holland [0:30]Definitely bikes. I grew up as an avid mountain biker. My dad was into it, and my uncle owns a bike shop in Idaho. When I was little, I would spend time in the shop when we visited, pretending to help but mostly just bothering him. I rode bikes as much as I could growing up. The bag side came later in college when I was preparing for a bikepacking trip. The bike I had didn’t fit any off-the-shelf bags, so I found an online guide on how to sew your own bag. I never considered sewing something that wasn’t clothing before, and I just fell in love with it.

Jeff Barber [1:16]Did you have any experience sewing before that?

Wes Holland [1:22]Not at all. I bought a Singer heavy-duty sewing machine from Joann Fabrics for about $200, ordered some fabric online, and got to work. It took me two weeks to finish that first bag, and I ripped it apart multiple times due to mistakes. I knew nothing about sewing when I started.

Jeff Barber [1:46]How did the bag turn out?

Wes Holland [1:48]It’s tough to answer because I tend to dislike everything I make. When you spend so much time staring at something, it’s hard to see past the flaws. But looking back now, with a decade of hindsight, I’m pretty proud of it. My wife even framed it as an anniversary gift. Technically, it’s not great, but it’s flannel-lined and waterproof. It’s not bad for a first attempt, though it’s nowhere near what I can do now.

Jeff Barber [2:31]Do you still see imperfections in your current work that others might not notice?

Wes Holland [2:48]Absolutely, on every single bag. I’m a perfectionist, and I often have someone else help with merchandising at trade shows because all I see are tiny flaws. Even factory-made bags have minor issues if you look closely because they’re still handmade.

Jeff Barber [3:27]Are you good at spotting fake designer bags?

Wes Holland [3:35]I haven’t tried, honestly. The designer world is foreign to me, but it could be a fun game to play—buy some knockoffs and see how they stack up.

Jeff Barber [3:53]What kind of riding do you do now?

Wes Holland [5:11]These days, most of my riding is commuting due to my schedule and where I live. But I started with mountain biking, and it’s still my passion. I grew up near the Fells Reservation in Boston and later went to college in Boulder, Colorado, mainly for the biking. I got into bikepacking, road riding, and gravel riding out there. Now, I do a mix of road biking, mountain biking, and downhill, but I ride every day to work, to get groceries, etc.

Jeff Barber [6:08]How’s the riding scene in Boston?

Wes Holland [6:19]It’s good, though we don’t have the elevation or weather advantages of places like Santa Cruz or Boulder. Our local groups, like NEMBA, do a fantastic job maintaining trails, and there’s a strong biking community here. There’s also a great cyclocross race circuit and a solid bike commuting scene around Boston.

Jeff Barber [6:50]Your first bag was a frame bag, which often requires customization. But you also sell hip packs and handlebar bags. What’s your approach to these more standardized products?

Wes Holland [7:27]It varies by bag. When I make something new, I try to do something different without adding gimmicks. For example, my smaller handlebar bag, the Cafe Cruiser, is similar to other small handlebar bags because there are only so many features you can add to something like that. But I offer custom colors, which a larger company wouldn’t. With my larger bar bag, the Bar Crawler, I added unique features like an extra loop for mounting stability without needing a rope to the frame. My hip bag, the BFP, is packed with features, including a cargo net for extra space when needed.

For me, the appeal is offering something made locally with care and intention. The value proposition isn’t always about differentiation in the product itself.

Jeff Barber [10:30]You make a good point. We often say we want the most functional and performant gear, but aesthetics and story matter too. I noticed your hip packs aren’t cheap. What makes them so expensive?

Wes Holland [11:24]For the BFP, the material costs are significant, but labor drives up the cost. Sewing involves much more than just stitching—there’s marking, cutting, pinning, etc. The BFP is labor-intensive because I wanted it to be perfect for mountain biking, even if that made it expensive. I didn’t want to make something that was just okay.

Jeff Barber [12:38]Even in a factory, making a hip pack is labor-intensive, right?

Wes Holland [13:04]Yes, but factories have advanced technology, like CNC pattern machines, that automate skill-intensive steps. They also use automated cutting, which is a huge time-saver. I’m still doing a lot manually, so that’s where the difference lies.

Jeff Barber [14:19]What materials do you use for your bags?

Wes Holland [14:34]I use three main types: liner fabrics, medium-weight fabrics, and laminates. Liners are lightweight for the insides of pockets. Medium-weight fabrics, like Cordura, are common in outdoor bags. Laminates, made from sailcloth, are popular because they’re strong, waterproof, and lightweight. Almost all of these materials are synthetic, usually nylon or polyester.

Jeff Barber [16:26]Tell us about your shop setup.

Wes Holland [16:36]I just moved into a new space two months ago. I have a cutting table with a pull-cut system for quickly cutting fabric, three straight stitch machines for different fabric weights, two bar tack machines for reinforcing straps, and an edge binding machine for finishing seams. I accumulated most of my equipment slowly, finding deals on Craigslist and Facebook Marketplace.

Jeff Barber [20:32]What’s the trickiest part about making a bag for biking?

Wes Holland [20:41]For off-the-shelf bags, it’s about consistency. I need to make them the same way every time without losing my mind. For custom bags, the hardest part is measurement, especially when the customer isn’t local. I prefer to take the measurements myself to ensure accuracy.

Jeff Barber [24:00]Can you reuse measurements for the same bike frame?

Wes Holland [24:15]I’ve saved all the measurements, but I haven’t had the same frame and size roll through yet. I’m sure one day I’ll have a library of them, but not yet.

Jeff Barber [25:33]Have you had any design failures?

Wes Holland [25:57]Plenty. Failure is a big part of the process. I have a tote full of failed prototypes. Sometimes the numbers don’t work, and I can’t sell a bag at a reasonable price. I’ve had some wild ideas, like quick-eject koozies for bikes, that didn’t work out.

Jeff Barber [28:27]Do you have plans to scale the business?

Wes Holland [29:01]My goals are modest. I don’t want to outsource production, but I do have seasonal help. I’m also experimenting with a laser cutter to ease some of the production pain points. I want to keep production in-house because I started this out of a love for sewing, not just to run a business.

Jeff Barber [30:24]Do accessory mounts on bikes make bag fitting easier?

Wes Holland [30:56]Not necessarily easier, but they make things more interesting. For frame bags, mounts can complicate things because they add rigidity where it’s not always needed. I prefer straps because they’re more flexible, though I do appreciate the mounting options for other accessories.

Jeff Barber [33:16]Do you have tips for avoiding frame damage from bag straps?

Wes Holland [33:59]Helicopter tape is the way to go for protecting your frame. Also, keep the straps clean—dirt acts like sandpaper. Regularly clean your bike and bag to prevent damage.

Jeff Barber [36:53]What’s in your hip pack when you’re out riding?

Wes Holland [36:53]I carry a flat kit, multi-tool, CO2, gloves, sunglasses, a first aid kit, and snacks. If it’s cold, I’ll pack a vest. I use the BFP hip pack, which has a water bottle holder, or a hydration backpack for longer rides.

Jeff Barber [39:01]Any plans for future products?

Wes Holland [39:20]I offer custom backpacks and am working on a hydration backpack. I’m focusing on personalized features like adjustable straps and different strap styles. It’s a slow process, but I hope to have something ready soon.

Jeff Barber [41:59]Thanks so much for taking the time to chat, Wes. I learned a lot about how bags are made.

Wes Holland [42:12]Thanks, Jeff. I really appreciate it.

Jeff Barber [42:15]You can find out more about Wes’s bags at bullmoosesoftgoods.com. We’ll have the link in the show notes. Thanks for listening.