In reply to captain paranoia:
> (In reply to pec)
> There are plenty of threads about making down gear on www.backpackinglight.com MYOG forum, with all sorts of cunning plans with hoovers, PVC plumbing, etc... >
Brilliant, thanks for that pointer. Its not a very easy website to search but I found just what I was after and I'm well on my way to refilling it, what's more with hardly any spillage and no taking my clothes off in tents etc!
In case anyone's interested (or is mad enough to be searching the forums in future for how to do this) here's how it works.
You need some accurate kitchen scales which measure to the nearest gram and a hoover with a flexi hose and one length of detachable rigid tube (i.e. most hoovers). Empty the hoover so it sucks better.
Fix some fine mesh (mosquito net or tights etc) over the nozzle on the flexi tube with an elastic band back a few inches so you can get the tube over it. If the tube goes inside the nozzle you might have to put the mesh on the tube instead.
Start sucking down into the tube where it gets trapped by the mesh. It quickly loses suction but a little assistance with your finger helps get more in.
Turn off the hoover and separate the nozzle and tube. A plug of compressed down will be at the hoover end of the tube so separate them carefully and push the plug back up the tube a couple of inches with your finger.
Weigh the tube + down and subtract the weight of the empty tube. You can suck a bit more up or pull some out at this point to get the amount you need.
Insert the end of the tube into the baffle to be filled, push it well in away from the opening and hold the fabric tight around the tube to minimise loss. Blow hard down the tube and the down pops out a treat.
Fold over the end of the fabric and clip with a peg to stitch later.
Put the tube back on the flexi hose and begin by sucking up any spillages before filling the tube again. Hoover the area you're working in first so you only hoover up spilt down and not random filth.
Its a bit slow but does work really well and with remarkably little mess.