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Ok, You gotta try on packs, You just gotta. For him being a scout (Eagle scout here, 20+ years in, Asst Scoutmaster of my old troop now (inactive for the last 18 months or so)), I would stick with Jansport, Kelty, or CampTrails. They are Cheap but have good quality. Get external frame. They are alot more forgiving of poorly packed packs, and If he's <15, it's gonna be poorly packed.
For sizing a pack, the belt is everything. 80%- 95% of the weight (depending on loading and adjustments) is carried on th hips. You want a nice comfy belt, lots of padding, but structuraly strong. Doesn't roll or deform when weighted. The majority the pressure is on your Ischeal Crests, which is the bony prominence of your hips, so make sure you have decent padding there. Also make sure there is a load-lifter strap on the hip belt. This is an adjustable strap that pulls the load from the back or your pelvis to the front. This is most critical, as will severly reduce fatigue and back pain over the length of a trip.
For torso length, the best way to do it is to try it on, as the majoroty of packs (especially external) have adjustable torso lengths, usuall 10"+ ranges. The padded shoulder straps should come off the back of the shoulders no less than level, a little up slope is good. The shoulder straps are there mainly to just keep the pack from falling off backwards, they have little actual load bearing function at all. Make sure these too have load-lifter straps. Just like the hip belt, these are adjustable straps that raise above the padded strap and are adjustable like grabbing a parachute or pulling an ejection handle.
Put about 20 pounds in the pack to try it on, the stores will have sandbags or the like. put about 12-15 lbs in the bottom compartment, and the rest in the mid-upper sections. Keep it kinda snugged up to the back of the pack. To put on the pack, Put it on like a jacket first, resting it on your knee when you lift, then swing it around, placing the arms through first, keeping all the straps loose. Then buckle the belt, snugging it up fairly tight at the buckle, while bouncing the pack up slightly to get it resting on your I-crests. Then snug down the shoulder straps, not too tight, not too loose. Then pull the belt load-lifters as tight as possible, you will feel the load literally swing around to the front of you. Then snug up the shoulder load-lifters. Having the load-lifters properly tensioned, the pack load should feel like it is part of you, pulling straight down on your spine, not pulling you backwards. I used to carry a 70 pound pack on longer trips (2 weeks +), and having this load properly balanced was criticial. I now only carry a 25lb pack and my 50lb dog carries a 40lb load and she loves it.
Things to note on the Packs.
Zippers. Big beefy zippers, preferable KKY manufacturer, are the best. If the pack doesn't have them, spend the $3 and get a dozen zipper pull tabs to put on the zippers.
Color. Personal choice, but earth tones and subtle colors are nicer to look at for the rest of your group. Anoither Facet of the Leave no Trace Ethic. Was on a 100 mile trip with a guy who had a bright orange pack. Really annoying to follow him. Save the bright colors for your emergency poncho.
Speaking of ponchos. Get a good pack cover. Or a Pack poncho that covers both you and your pack. Also pick up a can of Nikwax or like Nylon Water proofing spray. Spray the pack, this will help keep the moisture out.
Beaver Tail. This is a big flap that is sewn to the bottom of the pack that covers the back of the pack. It is great for stowing a jacket or like stuff. External frames rarely have these, but makes sure there is plenty of places to quickly and easily attach soft good to the exterior of the pack for drying and easy access.
Water. Some way to very easily access a water source is key. There are multiple ways to do this. Some packs have pockets on the lowere sides where you can reach back and grab a bottle, or you can get an addon holster for the belt. I have a 3 liter Dromedary bag with a hose and bite valve attached to my pack.
Couple other things:
Stoves. Because its scouts and Kids get stupid, stay away from liquid fuel stoves. Go with a butane cartridge stove.
Hiking sticks. If you want to dump a little cash on yourself, get a pair of hiking staves. Preferably the spring loaded Leki style. Look a lot like ski poles. With proper technique, they take some weight off your back, and increase your pace with less energy output. George Orwell said it best "4 legs good, 2 legs bad".
Ok I've spewed enough for now. IF you got Questions on any thing else, just ask. This business may be the one thing I know more of than poker.
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