Most riders know their chest, waist, or inseam, but few find armor that truly fits – whether you have a "beer belly," a petite frame, or a linebacker build. That "medium" shirt might fit your shoulders perfectly, yet the elbow armor can slide down your forearm or sit too far back on your elbow.
After 25+ years in the motorcycle protection business, We've heard this frustration constantly. Most moto gear is designed for a "standard" rider that doesn't exist. When armor doesn't fit right, it shifts away from the joints it's supposed to protect – and sliding elbow pads won't save your skin if they're protecting your bicep instead.
Bohn Body Armor solves shifting gear issues with sizing, keeping armor in place for proper protection on every rider.
The good news? We designed Bohn Body Armor's sizing system specifically to solve this. Real measurements, real bodies, real protection that stays where you need it.
Bohn Armor Is Designed to Fit Every Rider
Every Bohn product is built to hug the body, keep armor exactly where it belongs, and move naturally with you. Rather than offering a single “best fit,” Bohn designs its gear using different fabrics to match how and where riders ride.
Cool-Air Mesh Fabric
Designed for hot-weather riding, this lightweight mesh maximizes airflow while keeping CE-Level 2 armor tight to the body. Ideal for summer rides, commuting, or riders who want maximum ventilation without sacrificing protection.
Original Lycra™ Fabric
Soft, stretchy, and low-profile, this fabric is made to slide easily under jeans or riding pants. It offers a second-skin feel that keeps armor from shifting, making it a favorite for everyday and casual riders.
Get the AirTex™ Shirt with Lycra™
Performance Thermal Fabric
Built for cooler conditions, this fabric adds approximately 10-15°F of warmth while maintaining the same secure, body-hugging fit Bohn is known for. Perfect for cold mornings and extended rides.
No matter the fabric, every Bohn base layer is engineered with the same goal: consistent armor placement, all-day comfort, and a fit that feels natural both on and off the bike.
Get the Performance Thermal Shirt
Why Sizing is More Than Just a Number
Your jean size is often lying to you. Most fashion brands use "vanity sizing," so a size 34 waist might actually measure 36 or 38 inches. Because our armored pants are designed to fit under your clothes, we use your actual measurements to ensure the armor sits correctly on your hips, tailbone, and knees.
Loose-fitting gear undermines the idea of “dress for the slide.” In crashes, riders experience sudden impacts, bumps, and rolls – not long track-style slides. When armor is worn too loosely, it can shift on impact, leaving joints unprotected when they’re needed most.
Bohn armored pants use real measurements for a snug fit, keeping armor over hips, knees, and tailbone for real-world protection.
If you don’t feel the armor, it might not be working. Good protection should feel snug and hug your body so it moves with you, not around you. This snug fit helps ensure the pads are already in position before you hit the ground.
The Bohn Fit Philosophy: Why We Use Lycra™
When we started designing gear in 1997, we noticed a major problem: traditional motorcycle jackets and pants were often stiff, bulky, and restrictive. Riders would buy gear that was too loose just to be comfortable, which meant the elbow and shoulder pads could rotate away from the joint instantly.
We took a different approach. We use high-quality fabrics like Lycra™ and performance mesh to create a base layer that fits like a second skin. This "comfort-first" design ensures the armor is held securely against your body.
Bohn gear uses Lycra™ and mesh for a snug, comfort-first fit, keeping armor secure and concealable under any outerwear.
This approach solves two problems: Retention – the snug fit keeps the armor where it should be over your elbows, shoulders, knees, and hips, especially during a crash; and Concealability – because the fabric contours to your body, you can wear our shirts and pants under almost any outerwear.
Understanding Our Size Range (3XS to 5XL)
One of the things I am most proud of is our commitment to fitting every rider. We know that riders aren't all built like mannequins, with some customers as short as 4'9" and others as tall as 6'10".
For the "Hard to Fit" rider, if you’ve struggled to find gear because of a long torso, broad shoulders, or a "beer belly," you are exactly who we design for. Many European brands like Pando Moto or Knox often cater to slimmer riders, which can make their gear feel tight and restrictive for everyone else.
Bohn fits every rider from 4'9" to 6'10" with real-body sizing, stretch Lycra™, and armor that stays perfectly in place.
Our sizing runs from 3XS to 5XL, with options for Tall, Short, and Big builds. Tall riders get longer inseams and torso cuts, petite riders get armor that fits smaller frames, and plus sizes benefit from stretch Lycra™ and adjustable waistbands without compromising armor placement.
The Critical Role of Armor Dimensions
Sizing isn’t just about the fabric – it’s about the armor coverage. Many competitors use small, "coin-sized" pads that only meet the bare minimum for certification, but we don’t believe that’s enough for the realities of the road. Proper coverage matters when impact protection is the difference between walking away and getting injured.
We use high-quality viscoelastic foam from SAS-TEC for our armor. This material is soft and pliable against your skin but hardens instantly upon impact. More importantly, we use massive coverage zones to protect critical areas of the body.
Bohn uses oversized SAS-TEC armor for full joint and limb coverage, delivering real-world impact protection beyond minimal pads.
Our elbow and forearm armor is a single piece measuring 5 x 12 inches, protecting both the joint and forearm, while our knee and shin armor measures 5.25 x 12 inches for above-average lower-leg coverage. We also use substantial shoulder cups that wrap around the joint.
Choosing the Right Fabric for Your Climate
Fit is also about thermal comfort. If you are overheating, you become fatigued and distracted, which is a safety risk.
For Hot Weather: Cool Air Mesh – If you ride in the heat and humidity of the US South or West, our Cool Air mesh is a game-changer. It allows air to flow directly to your skin, wicking away sweat. It fits snugly but has slightly more structure than the Lycra™ options.
For All-Year Riding: Original Lycra™ – This fabric is like high-end yoga wear-super soft and incredibly stretchy. It is fantastic for fitting under tighter jeans or leathers because the material is so smooth.
For Cold Weather: Performance Thermal – These pieces are lined with a soft, fleece-like interior that traps heat, adding about 10-15 degrees of warmth to your ride. Note that the fabric is slightly thicker, so it will feel a bit snugger than the Cool Air mesh, but the sizing chart remains consistent.
How to Measure Yourself Correctly
To get that "perfect fit" the first time, grab a fabric tape measure.
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Waist: Measure where you actually wear your pants. For many men, this is under the belly. For women, it might be at the natural waist or hips depending on the cut you prefer. Our pants have an elastic waistband to accommodate fluctuations. A good rule of thumb: use your jeans measurements and follow the sizing guide.
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Inseam: Measure from your crotch down to your ankle bone. Remember, our armor covers the shin, so you want the length to be correct so the knee pad sits on the knee, not the thigh.
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Chest: Measure around the fullest part of your chest, under the armpits.
If you find yourself between sizes, think about how you want to wear it. If you prefer a compression-style fit (which is great for keeping armor rigid), size down. If you prefer a little breathing room, size up. However, remember that our gear is designed to be body-close so sizing up is usually not recommended.
If you don't see your specific size or combination, please reach out to us. We may be able to custom-fit an item for you or recommend alternatives.
A Note on Abrasion and Layering
A common question regarding our sizing is, "What do I wear over this?"
By design, Bohn armored shirts and pants are not abrasion-resistant. This is intentional – it keeps them lighter and more breathable than heavy Kevlar®-lined gear.
For the best protection:
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Casual/City: Wear your Bohn base layer under a pair of abrasion-resistant jeans (like those lined with DuPont Kevlar®) or our Bohn Flannel, which features Kevlar® thread woven throughout the entire garment.
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Highway/Track: Pair Bohn with heavy leathers or a Cordura shell.
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Adventure: Throw a lightweight mesh shell and cargo pants over your Bohn armor.
The beauty of this system is that you buy one set of comfortable armor and wear it for up to 10 years under whatever outer layer your ride demands.
Frequently Asked Questions
Can I wash my Bohn Body Armor?
Yes! The removable armor system allows you to take out all the pads – shoulders, elbows, back, hips, knees, and thighs – and throw the fabric shell in the wash. This is great for keeping your gear fresh after a hot summer ride.
How long does the armor last?
We use high-quality SAS-TEC armor designed to last 5-10 years before its impact protection abilities begin to degrade.
Will these fit under my regular jeans?
Absolutely. Our "invisible protection" design means you can wear them under almost any outerwear, including Levi's, Wranglers, or slacks. If you wear very skinny jeans, you might need to size up your jeans, but for regular or relaxed fits, they slide right underneath.
Is the back protector included?
Yes. Our shirts come with a CE-Level 2 back protector, along with shoulder and elbow/forearm armor.
Where are your products designed?
Our team is based in Mooresville, NC, and our products are designed in the USA. We have quality control right here to ensure every piece meets our standards.
What is your return policy if it doesn't fit?
We want you to be happy and protected. We offer free shipping on orders over $109. If the fit isn't right, our team is here to help you exchange it for the correct size.
Does the armor cover the tailbone?
Yes, our armored pants include tailbone coverage, as well as protection for the hips, thighs, knees, and shins.
Why don't you use hard plastic armor?
We use viscoelastic foam because it is flexible and comfortable while you are riding, but absorbs energy efficiently upon impact. It can also be reused after a crash, unlike some hard armors that crack.
