Tailfin AeroPack Cargo: Refined Performance

Over the past year, I've been fortunate to use the original Tailfin AeroPack on my gravel bike. From work commutes to week-long bikepacking trips, I use it frequently enough to leave its mounting axle on my bike. It's amazing how quickly this rack system can be installed or removed from the bike, so I've always been happy to have opted for the AeroPack system rather than the AeroPack and trunk bag.

From day one, it's felt like a near-perfect rear bag. It's wildly stable because of the rack system, but light enough that I'll also use it on long day rides without worrying about the extra weight. From a size perspective, it holds sufficient without inviting any overpacking syndrome. It can hold my full sleep kit and a 2-person tent or my 14-inch MacBook, some work clothes and a hungry cyclist's lunch for my work commutes.

Despite everything I love about the original AeroPack, it did have some quirks that never felt quite right: the four buckles to close the main compartment seemed a bit excessive and awkward; the zippered side pocket was too small to carry much, especially when the bag was packed full; The side zippered access on the other side wasn't all that practical for anything other than quickly releasing air as I roll it close; andif the bag wasn't full to the brim, the extra strap length on the rear would cover the Tailfin rear light mount.

When the opportunity to test the new AeroPack Cargo came up, I raised my hand. Not only does it seem to address all my issues with the original, but it also looks to have added key features that will undoubtedly perform better.

About Tailfin

Tailfin is a top-tier bikepacking gear maker, with a reputation trusted by many of the top bikepack racers. In the past year, they've expanded their catalogue, releasing this updated AeroPack, the Bar Bag System, frame bags, fork-mounted bags and long Top Tube Bags.

Every product is thoroughly tested by their global R&D team of riders and racers. Anyone with a keen eye can spot their up and coming products on social media. They're often hidden in plain sight, with Lachlan Morton using variations of the AeroPack Cargo on his 2023 Tour Divide and 2024 Australian record-setting epic ride.

Because they prioritize quality and design, Tailfin products carry premium pricing; however, their performance and longevity justify the added expense. Depending on your rack choice, prices range from $360 to $510 USD. For those outside the UK ordering online, remember that the added shipping, import duties and/or tariffs will inflate the price even more.

Getting the Right Axle

The first step is determining the correct thread pitch. Frames can have a 1mm, 1.5mm, or 1.75 mm thread pitch and the best practice, before ordering, is to take the time to pull the axle off your bike and visibly verify it. When I was first setting up my gravel bike, I consulted my bike manual and ordered the wrong axle. It turns out the manual wasn't updated when the manufacturer upgraded the frame with UDH dropouts. We also had to order yet another axle for my wife's bike.

Tailfin also offers a Universal Thru-Axle ($75 USD) that takes this guesswork out of choosing your axle and also future proofs you in case you swap bikes or upgrade bikes. This axle has four swappable threaded ends that cover almost all axle thread pitch standards from 1.0mm–1.75mm, including 1.0mm double lead for Mavic Speed Release and widths up to 148mm boost spacing.

For anyone using a UDH you will also have to order the SRAM UDH/Eagle transmission adapter ($15 USD). Frustrating as it was, my bike came with an aftermarket UDH (non-SRAM) with a different thread pitch than the SRAM adapter, requiring yet another part swap. However, once we got over the initial pain of figuring out my specific axle & adapter needs, the rack/bag system is incredibly intuitive, quick and easy. It snaps on and off the bike in seconds.

On a positive note, the AeroPack system performs equally well on full-suspension mountain bikes. For bikes using a dropper post, or for bikes with minimal seatpost clearance, it's worth considering the Tailfin extended seat post connector, which slides the bag back behind the saddle. It's proven essential on my mountain bike and on my wife's 54cm gravel bike.

Design & Construction

Like every Tailfin product, the AeroPack Cargo is designed beautifully. The main compartment is a sizable 18L rolltop dry bag. Two large stash pockets along its sides, adding 3L of expanded external storage, which are cinched up with a single Voile-style TPU strap over the top, keeping the contents nice and secure. Overall, the quality inspires confidence. In nearly 12 months, my original AeroPack setup still looks brand new despite 5000 km of use. I would expect similar durability with this new bag.

Little details truly stand out compared to the older model. On the outside, the external TPU strap is adjustable, quickly adapting to fit any load. It can be shortened to snugly fit around a minimally packed setup or lengthened to hold firm on a jammed-to-capacity bag or extra items resting on top. Underneath the main compartment, on the rear of the bag, there is a new bottle mount position. While it might not be an intuitive place to carry another bottle, it is a great place to secure camp fuel or a tool kit. As always, the rear of the bag has Tailfin logos in a reflective font and a series of small attachment points for lights.

Inside the main compartment, Tailfin uses a new light colour base inside the bag, unlike the original bag, which left you aimlessly groping for items in almost any lighting condition. It's a tiny detail that makes a big difference. The two most notable improvements are the added air valve and the faster closure system. The air valve opens with a quarter turn, making it easy to push the air out as the bag rolls shut. The new closure system is a single buckle that closes back on itself. This not only makes it faster to open and close, but also lends a much cleaner look to the bag. Not visible, but important to mention, is the internal frame. It's been redesigned and is more rigid to help the bag hold its shape.

Understanding Tailfin Rear Racks

For anyone new to Tailfin products, there are two different rear rack systems that I must explain. With the AeroPack system, the top bag is the integral spine of the rack frame, which includes the seatpost attachment and the legs that clamp to each side of the thru-axle or frame. These forked legs are available in alloy or carbon, with or without pannier mounts. Which means you always require the top bag (being reviewed here)

The second system, Tailfin, calls the Pannier Rack, which is a standalone rack, designed with similar attachment points; however, this rack requires the AP18 top bag that attaches directly to the rack, allowing you to run panniers without the top bag. The AP18 is available in the original Standard or the new Cargo version that we're talking about here. This rack is also available in carbon or aluminum. Carefully consider this when ordering.

Usage & Performance

I've only used the new AeroPack Cargo for about 600 km of riding, spread across just 4 rides. Because of my experience with the original version, I quickly understood the improvements.

I've been training for the upcoming Traka Adventure, so I've been logging big days and making sure to always ride a loaded bike. My first ride was a 205-km route on Vancouver Island from Cumberland up to Campbell River, around Upper Campbell Lake, and back along the ocean to Courtenay/Comox. The route is mostly gravel, with about 50km of pavement and maybe 30km of trail or doubletrack. I carried a reasonably full load, with extra layers, full rain gear, and food and water for the entire ride. I even packed my food in Tupperware, which can be difficult to keep in place and takes up unnecessary volume.

Other rides followed similar packing strategies and terrain choices, mixing rough terrain with pavement, gravel, and short sections of singletrack. They were all on my carbon racing gravel bike with steep geometry that focuses on speed rather than comfort. Although I ride on plush-feeling 44mm tires running low pressure, it isn't the smoothest ride. This provided a great way to test bikepack gear, especially to see how it performs in rough terrain, on a rough bike. On every ride, it was obvious that the new AeroPack Cargo is exactly what it should be: a well-thought-out improvement compared to its predecessor.

I had noted from the original system that it does feel a bit stiffer and subtly changes my bike's handling because it carries the weight slightly higher, as the loaded bag is just a little taller. However, this was easy to get used to with the rack's incredible stability. The AeroPack prevents the bag contents from swaying at all. I worried the simplified closure system might be less secure, allowing the contents to shift about during rides. Even driving the pace on rough singletrack, it proved to be resilient. If anything, the stretch of the TPU strap is easier to tighten firmly. It's simply a matter of adjusting its length to make sure there is firm tension holding the bag down.

A huge advantage of the new system is improves access without having the original 4-buckle system. When I bikepacked across Belgium and France last October, I was constantly adding and removing layers. Those four buckles were always a pain to open the rear bag. When I was wet and cold, these were particularly finicky and required constant micro adjustments if I removed or added substantial volume. In similar conditions this spring—riding in occasional rain, snow, and sun—I was in and out of the bag up to a dozen times on each ride. The new design is so much faster and convenient that it's hard to describe. The biggest plus is that the fiddly, micro adjustments are largely gone. It's now a matter of simply rolling the bag tightly closed and clipping a single oversized buckle. The TPU strap can be quickly pulled tight to secure everything.

The stash pockets also make it easy to quickly—wait for it—stash gear. I treated them like a jersey pocket, quickly stowing my wind layer during climbs before pulling it back on for a downhill. I can imagine that's where I'll be keeping my spare Haribos during the Traka Adventure, too.

Most noteworthy, I've yet to notice a single drawback. Although Tailfin still offers the original AeroPack alongside the AeroPack Cargo, it wouldn't surprise me to see the new version serve as a permanent replacement soon.

Conclusion

I've owned the original Tailfin AeroPack for more than a year and loved it. It was an outstanding design that made bikepacking easy, on nearly any bike. Still, it had a few weird design choices that I never understood, and it seems I wasn't alone. My main complaints about the original have all been addressed.

The simplified rolltop that locks back on itself, with a single Voile-style TPU strap providing the compression to keep loads secure. It's faster and equally stable. Two stash pockets replace the almost unusable side pocket and side access zippers. These are far more functional, providing an easy place to store wet gear or layers that will get used throughout the day. These pockets can also be adapted easily, making it easy to hold more gear and odd-shaped gear in place. At the front of the bag, they've added the same one-way air valve Tailfin found in a number of their bags, including the new bar bag system. It makes closing the bag and reducing its volume simple and should be standard on every waterproof rolltop bag in existence. There is also a new standard bottle mounting point, perfect for carrying fuel or a toolkit.

Overall, if you already own an AeroPack, it might be difficult to justify the $260 USD upgrade cost, but fortunately, the hardware remains compatible. It's simply a matter of swapping out the bags rather than an entirely new setup.

If you're new to the Tailfin ecosystem, the new AeroPack Cargo refines an already standout product line. I cannot think of a better rear bag system, especially if you're transferring it between multiple bikes. I am sure I'll be happily using mine for years to come.