Bad design is bad design regardless if it has an "H" or a "Typhoon" or whatever on it. My every experience with that much basic stress and tension on cheapo nylon zippers is that they fail by splitting somewhere along the zipper. Coupled with the pulling, twisting, turning and jerks on the pack that will obviously come walking and hiking will add. I give the zippers of that bag 3 months tops. And like I said --the nasty thing about it is that when it fails it will be past the point of returning it. It's called "planned obsolescence". From backpacks to plastic bumpers on cars and everything in between. The way of our whole "made-in-China-cheapo" economy is based --ALL so that the manufacturers can get rich quicker. Sorry but if I spend $150 - $180. ON A BACKPACK (!) I want it to last. I am NOT supporting their game so back it goes. I would have much rather spent twice the money if got something that would LAST. This piece of shyt --won't.
What other soft or hard case solutions have people found?
It is not a "bad design". If fact, it's a good, and much better, design than the original "hard" backpack. If you follow what several others have said, you will have no problem. First, put the lower foam (with, or without Typhoon H & accessories) inside the backpack, and position it fully inside. Next, place the foam top on top of the foam bottom. Finally, pull the "back" side of the backpack over the foam top, re-positioning it from side-to-side (to make certain it's centered). Once the "back" side is pulled forward, zip the zippers up both sides, but not over the top. Once both side zippers have been zipped up the sides, then carefully pull both "sides" (ie. top & bottom) of the backpack closer together, zipping the zipper as you do so. Do this on both sides, until the backpack is completely zipped. Then let it sit like that for 1-2 days, which will stretch the material properly (ie. the material has NOT been pre-stretched).
After it has sat, and the material has been properly stretched, then you will find you can (fairly...as the material finishes stretching over the next few/several days, it will become easier to zip/unzip) easily zip/unzip the pack. At this point, you can attach the Velcro to the foam upper, attaching them following the same procedure I listed about for zipping the backpack in order to stretch the material (ie. start with the bottom Velcro piece, then the top piece close to the bottom, then the side pieces & top piece close to the top, and, lastly, the top Velcro piece. It's not that difficult...and, in the end, everything will be exactly as it was designed to be.