Hi Matt, welcome back, hope your trip was all you hoped it would be.
Great, informative review. I have put together a similar setup, and can see where you ran into difficulty. For quite some time, I was wavering between a Zulu or Marauder, or a Camelbak BFM. The three packs are simliar size and configuration, although far different in price. I bought a BFM only because I snagged one on ebay for $100. I added a Kifaru Liter Plus pouch, Claymore Pouch and GPS Pouch.
I came to a similar conclusion as you did, size issues. A pack that size (with or without add on pouches) seems to fit in between needs. For EMS situations, it's too small for a week and too big for a couple days. This may be different for military applications, as the LF crew seem to say these packs are perfect for three day packs. I had planned on using it as a carry on. but am skeptical now based on your experience. It will be great when we deploy on military aircraft, but might pose a problem on commercial flights.
I'm going to look at the PullOut and Lock'n Load pouches based on your review.
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It's not that life is so short, it's that you're dead for so long.