A Guide To Building A Rolling Bug Out Bag
Updated October 2025.
Recently a friend of ours was training for a 3-day long off-trail camping adventure in Wyoming. He needed to carry a 40 pound bag and he was a little out of practice so he started training around town with a backpack full of weights.
He proceeded to walk 7 miles a day for several weeks. A few days after he started we were talking about it and he admitted that it was rough. He's in his 50's but is in excellent physical condition and always has been.
This experience was making him rethink his entire emergency preparations as well, since the bug out bag he had in his closet was close to 60 lbs, even before adding water to it!
His thinking led him to looking into ultra-lite gear, but we started talking about the cost of those types of products and the numbers got really high really quick. Fine, if you can afford it...
So what about us average folk? In my experience, most people get tired even carrying around 20 lbs for an hour or so. So how in the world can we handle our crazy-heavy emergency kits, especially during a crisis?
The same way we have since the start of history, wheels!
Wheeled Emergency Kits
There are several factors to consider when we start talking about kits with wheels vs backpacks. First off, backpacks are easier in many respects to handle and get around obstacles with, since your legs are the support system. But that brings us back to the problem of weight.
Wheeled bags, like suitcases, roller-boards, and the like can make carrying heavy loads easier but are mostly useless once you take them off of a smooth paved surface. This is mainly because of the tiny, hard wheels most luggage has. So they are limited in where you can reasonably take them.
So we need to find a sweet-spot, a compromise between weight capacity and maneuverability. This can be achieved in a number of different ways:
- Standard Luggage plus backpack
- Multi-Terrain Cart or Wheeled Bag
- Bit of Both: Backpack + Wheeled Bag
Where you live will determine what your needs would be. If you are in the city or suburbs, it's likely there will be some manner of pavement in most of the areas you will be. If you are rural then you will need bigger wheels, something that can handle dirt, rocks, sand or snow.
We'll go through each of these options, it will be up to you to decide what makes the most sense for your specific situation.
Standard Luggage + Backpack: a Quick Compromise
Let's assume you already have your bug out bag(s) made in a backpack and like most, it is really too heavy to wear for a long time.
One option would be to throw it into any wheeled luggage you already have. Just dump it in there. Now you can put the suitcase in the car and you're good.
If things get hairy and you have to ditch the luggage and put the backpack on, so now you are carrying the load on your back, but at least you aren't lugging it around the whole time if you don't need to. Your back will thank you, so will your feet and hips. You older folks know what I'm talking about!
If you are in the market for new luggage anyway, try to find some with extra large wheels, like this bag from Laduga. It has 5.2" wheels which will make getting over uneven terrain easier than your standard luggage wheels.
Not suggested: don't build your primary emergency kit as just a suitcase without having all your gear inside a backpack. If the situation arises that you cant roll it, you're carrying it in your arms. That can be dangerous and will get tiring pretty quick.
If you cannot wear a backpack due to a physical condition, then try to find something that will either integrate into your transportation system (i.e. a wheelchair) or that has backpack straps so that someone else may be able to carry it for you.
Multi-Terrain Cart or Wheeled Bags
Throughout history humans have searched for ways to carry their stuff around. The answer many times was to use some manner of animal for assistance, like a horse or mule. Unfortunately nowadays that's not an option for most of us.
Of course, we have motorized options which are superior in many ways. But if fuel becomes an issue then they become useless.
So this leaves us with human power to carry out loads. Off-road this this predominantly means backpacking.
Monowalker
Surprisingly there don't appear to be many alternatives to the backpack when it comes to all-terrain non-fuel-powered travel. One item that seems to be effective and viable is the Monowalker. It's essentially a modern-day modified wheelbarrow that has shoulder and waist rigging.
It's pretty ingenious, and looks very workable. Check out this video from Canadian Prepper. He's used his like crazy to haul 90 pound loads all over the Canadian wilderness. He has good perspective on what it can and cant do:
And though this seems to be a great idea, at $1000 a Monowalker isn't going to cut it for most people. As nuts as we are over emergency gear over here, that's even a little too steep even for us.
All Terrain Carts
Mac Sports makes a few varieties of folding cart. Our choice would be their Heavy Duty All Terrain model. It can hold up to 150 pounds, and can fold itself up to make it a little more convenient for packing into a car or storing.
Although the wheels are of decent size, they are plastic ad somewhat smooth so you are still going to do best on hard or semi-hard surfaces. I don't see these performing well in powdery sand or mud (purchaser reviews on amazon confirm as much.)
Some complain they are noisy on pavement. On the upside they wont puncture or go flat, but once the plastic does go that's the end of it.
Also these are pull only. Being able to adjust between pushing and pulling is helpful to reduce fatigue and prevent injury.
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Wheeled Bags
There are a handful of manufacturers that make ruggedized rolling bags. There are a few that could be appropriate for use as an emergency kit.
Hazard 4 Air Support
Typical Price: $259 Size: 38.5 Liters
Designed for military use, the Hazard 4 Air Support has a bunch of features that will be useful for our purposes. Firstly they come with nice big wheels and a bumper reinforced back.
MOLLE attachment points adorn the front and side. This would enable us to add whatever pouches we please along the outside for organizational purposes.
I can see adding a scabbard to one side if desired. One could easily carry an axe where the compression straps connect by the buckles. You could also attach a backpack to the front side and use this to help carry it around as needed.
There are a couple of modifications I would make. Firstly I don't see the need for the long storage pouch along the top which serves as either a laptop bag or when reversed a scabbard. I would cut the pouch and resew it to make a smaller pocket.
I also am always afraid of pull out handles. I've had a few roller boards break where the handle meets the extending arms. Perhaps they could be reinforced in someway where they meet.
Hazard 4 also makes the larger Shore Leave bag, but to my thinking it's a little to large for a Bug Out Bag. Good for an INCH Bag perhaps or if you have a family and want to put all your stuff for them into one bag.
$449Hazard 4 $449AmazonAdd To Bag
Osprey
Osprey is a top of the line manufacturer of camping equipment, and they have a huge range of rolling bags that would be perfect for an easy to travel with emergency kit.
What we really like is their Sojourn series of Wheeled Travel packs, because the not only act as wheeled luggage, but also convert into a backpack so you are getting the best of both worlds.
They currently offer 3 different sizes of the Osprey Sojourn Wheeled Travel Pack: 28"/80L, 25"/60L, and 22"/45L. Pictured below is the 25"/60L and I like that sized pack for most people - its big but not too big.
Osprey Sojourn Wheeled Travel Pack 25"/60L
Typical Price: $420 Size: 60 Liters
The Sojourn 60 is a perfect middle-ground for checked-bag travelers who want to stay nimble. Oversized 90 mm wheels and a lightweight HighRoad chassis keep you rolling in comfort, and the stowaway AirScape backpanel and harness expand your horizons. StraightJacket compression straps cinch down packed items for added storage capacity. Included TSID luggage registration helps you reunite with your bag faster should it disappear during air travel.
Pros: Wheels! Straps! It has it all.
Cons: Wheels & Straps means its pricey and is on the heavy side at 8.2 lbs. 95% rolling / 5% on your back addresses the weight issue - I can't help you much with the pricing side unfortunately. For a more budget friendly options look at the Osprey Farpoint Wheeled Travel Packs or look on Amazon, they have a bunch of less expensive wheeled luggage with backpack strap options.
Dims: 13.78H X 17.32W X 27.95D IN.
Weight - 8.2 lbs lbs
Amazon Basics 35-inch Large Rolling Duffle
Typical Price: $100 Size: X-Large - 137 Liter
Pros: Inexpensive, and one of the most cost effective models available. Its lightweight yet roomy and can hold stuff for several family members.
Use in conjunction with packing cubes to keep it organized, or all your stuff will just wind up in a huge pile on in the main bag area.
External Size: 37.5"L x 16"W x 18.25"H
Cons: The construction quality is entry level. Do not expect this thing to take a beating. It will survive an airline ride or two but you will start to see degradation after that type of treatment.
I would not overload it with heavy equipment either - keep this bag for soft, lighter weight items like clothing and sleeping bags, etc. I would get some luggage straps to cinch it down along its width and as backup insurance if the buckles or zippers fail.
No list on BOBB would be complete without an entry from 5.11, one of our favorite suppliers.
5.11 Mission Ready 3.0 Rolling Duffle Bag
Typical Price: $325 Size: 90 Liters
The wheels on the will Mission Ready 3.0 handle up to 150 lbs. Moisture and weather-resistant. Skid rails for support and load displacement and fiberglass rod in the side panels. Replaceable heavy duty wheels, wheel housing, skid rails, corner protectors and U feet. Built to take a beating and just looks at you funny afterwards.
We've had one of these for years and use it to hold a ton of our camping gear. It get's put away packed and pulled out ready to go when we are hitting the woods.
Main Compartment - 28.75"H x 16.0"L x 12.25"D
Total Capacity - 5514 cubic inches / 90 Liters
Weight - 16.09 lbs
Folding Hand Trucks
One compact solution that is fairly versatile is a folding hand truck or cart. Many of them can carry up to 150 lbs.
You could strap a couple of backpacks to one with strong bungee cord and keep it packed away in a vehicle when not being used.
Amazon has a handful of them for under $30. There don't appear to be any made with all-terrain tires that we could find, but perhaps someone is making them.
Either way this would be helpful on paved surfaces. There are heavy duty and compact models available.
We have this Mount-It! Folding Hand Truck and Personal Dolly. It cost us $85 but we use it all the time for camping to haul 2 10L water jugs back and forth between our water source and our kitchen / shower.
If we had to evacuate our home for any reason this cart would be with us for sure. It's built like a tank and is extremely useful for a variety of tasks. The bottom platform is huge and we can stack all our gear on it in one shot since it holds 260+ lbs.
The wheels are nice and big and can roll over grass, dirt, and even mud and sand (if it isn't too deep) and I know, I've rolled it through just about everything.
Bit of Both: Backpack + Wheeled Pack
Having a little bit of everything is probably going to be the best case scenario.
Equip a backpack with your most important gear, and try to keep it around 20 pounds. Put the rest of what you want to bring in a wheeled something or other. If you need to ditch your wheeled bag at least you have the pack on you to give you a backup.
The backpack will probably be faster to get into for small items and is probably also the best place to carry the water you are drinking at the time.
Your wheeled bag can carry any spares or extras or some of your bulkier items. If you have 3 days of food, put day 1 in your backpack, put days 2/3 in your suitcase. You get the idea.
About the Author:
Mr. Bobb (aka Coach Bobb) is a nationally licensed EMT, avid camper and outdoorsman who has been studying preparedness for 15+ years. Member of his local CERT team and trained in Mass Casualty Events response as well as TCCC. Ham radio general class license holder. Inventor of the WUSH bag acronym (Wake Up! Stuffs Happening) and concept.
