Good post ... migration from lurker-only tells me you've gotten really hooked
My two cents:
• Radio looks approx. 5-in. x 2-1/2-in. Consider a smaller, lighter radio, one that uses same AA batteries as flashlight (unlike your current AAA-version). Eliminates need to carry two battery sizes, and allows inter-changeability.
• Consider replacing LED-conversion Mini-Mag with a reliable, two-level (low- and high-beam) AA-powered LED flashlight. Much of your use only requires a low-setting (cooking; map or other reading etc.), and will significantly extend run-time and battery supply.
• Include LED micro-flashlight as backup (two is better). They’re small, light, reliable, and inexpensive, with good run-times. Both Photon X-Light and Inova Microlight are about $6; 12-15 hour run-times with multiple brightness levels.
• A small 2-level AA-powered headlamp might be worthy of consideration as a back-up light.
• Second the recommendations to include duct tape (no disrespect to hockey tape), pea-less plastic whistle, ferro rod/metal match, spork, pencil (shavings double as firestarting tinder) and absolutely, a decent length of paracord.
• Might be better served to eliminate a couple of the five smaller garbage bags, and substitute a single, large 3- or 4-mil garbage bag … makeshift shelter, bivvy, sleeping bag, rain poncho.
• Personal preference, I carry the smaller, lighter DMT Diamond Mini-Sharp rather than a stone.
• Strictly a nit-pick, but saves a little bulk and weight – substitute a travel-size deodorant for your full-size Speed Stick.
• Since they add minuscule bulk/weight, consider including a couple of Tinder Quik Fire Tabs as backup tinder.
• As a substitute for your tea candles, take a look at Nuwick 36-hour candle-in-a-can or similar. Can be used for light, heat, and cooking, with “adjustable” output. Modest increase in bulk/weight over tea candles.
• As mentioned, consider eliminating the bulky/several ounce SAS Survival Guide. I’m sure you know much of the information anyway. Cut-and-paste useful info (knots, signaling, first aid, navigation etc.), and print two-sides on a sheet of 8-1/2 x 11-in. paper. Takes no room/weight, and in a pinch, doubles as tinder. Don’t feel like “reinventing the wheel?” Download and print Doug’s Pocket Survival Pak Survival Instructions in PDF, found here:
http://www.dougritter.com/psp_index.htm (near bottom of page).
• A tip for your BIC lighter: after having a couple of BIC lighters completely discharge the butane while in storage because the control button/tab/lever got depressed (you know how it is, trying to stuff that last bit of gear into a bag), I wrap a rubberband or thin cordage around the lighter several times, wedged between the main body and the underside of the control button/tab/lever. Prevents it from being accidentally depressed.
• Notice absence of signal mirror. For those times when you might want to be “found,” I’d include a small mirror, glass or good-quality Lexan, like Rescue Reflectors, Star Flash etc. Also useful when removing foreign objects from the eye.
• Like you (and Les Stroud) I always carry a good multi-tool, but the blade(s) are limited use. Consider a reliable but inexpensive folder to supplement your fixed-blade. Something like one of the four KABAR Dozier folder models at $19.95. A bargain in my opinion.
Good luck with your revised kit (of course, you know it will always be a work-in-progess).
Dan