I would like to gather ideas on making a more "realistic yet still fun" gathering and crafting system.
In wilderness survival, one cannot carry 50 logs, 4 wooden walls, 99 rocks, and a toothbrush. Carrying a decent sized log usually requires both hands and can use a good amount of energy. Of course, resting after carrying each log a certain distance is not fun, so lets ignore the energy usage.
Gathering
I want to address the amount of items in which a player can carry and how to go about crafting an item. My idea was to have a player chop down a tree, gather leaves and branches into a handy-made backpack, and use both hands to carry one log to your campground. Then go back to the fallen tree and get the other log. The controls and HUD would need to be perfect in order to ease the switching between carrying one item and carrying two.
Crafting
In order to craft a certain item you need to place all gathered items into one tile on the map. When you hover over the gathered items a a list of possible crafted items will appear. Click one to build it.
I was wondering if this idea would become too tedious? Tool building is relatively painless, but building a shelter would not. Remember, the goal is realistic wilderness survival.
Take a look at Cataclysm: DDA. It's the single best zombie survival game I've ever played, and the way they handle inventory management is simultaneously realistic and fair to the player.
The thing that makes Cataclysm DDA such a great example is that the consequences aren't trivial. You CAN lift that shopping cart, but you can't walk around with it. You CAN carry that felled tree, but you aren't going very far. You CAN walk around with a fridge-load of tinned beans, but you aren't going to be able to outrun any zombies you find along the way.
Cataclysm also offers the player lots of options to overcome these limitations by tying carry weight limits to the strength statistic, and also by giving the player the ability to use tools to modify their carrying capacities. You wind up relying on wheelbarrows and shopping carts early in the game to haul your crap, and unloading a lot of your spare crap into a base of operations that you've carved out for yourself.
You start to realize though that this reliance is actually a liability: It restricts you to surviving off of tinned beans, which are only found in cities. The shopping cart doesn't roll too well on soft earth, so you need to stick to roads. Unfortunately, the densest concentration of zombies are also where all your survival rations are, and the more crap you have on you, the harder it is to dodge their attacks and survive.
So you decide to move out to the country. Well, that's problematic because you need to haul around huge trees to make a log cabin, and you need to grow your own food or hunt wild animals just to survive. Unfortunately you can't manufacture gasoline, so you eventually run out of fuel for your truck and need to go raid a city for fuel. Only living on your own has made you psychologically weak to dealing with Zs.
C:DDA is a great exploration of the problems of being a lone survivor in a zombie apocalypse and offering the player a true sandbox experience. Give it a shot and see what you can learn from it.