Is your closet bursting with motorcycle jackets? You probably have a mesh one for July, a heavy textile one for November, and maybe a leather one for looking cool on Saturday nights. And the worst part? You paid for a set of cheap, bulky armor inside every single one of them.
I talk to riders every day who are tired of buying gear that only works for three months out of the year. That is why, over 25 years ago, we designed the Bohn BodyGuard™ System to be completely modular. Instead of buying a new suit of armor for every season, you own one world-class armor set and simply swap the "shell" to match the weather.
One armor set, multiple shells—the Bohn modular advantage. Source
If you are looking for a smarter way to ride—one that saves you money, closet space, and keeps you safer—this guide will explain exactly how our modular armor system works.
Top Picks to Start Your Modular System
If you want to stop overpaying for gear and start building a versatile system, here is where most riders begin:
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Bohn Cool-Air Mesh Shirt & Pants: Our most popular "shell" for hot weather. It flows maximum air while keeping armor locked in place.
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Bohn All-Season Airtex Shirt & Pants: The daily driver. Made from a soft, stretchy Lycra™ that feels like high-end athletic wear and works in 80% of riding conditions. Available in many colors.
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Bohn Performance Thermal Shirt & Pants: Turn your existing armor into winter gear. These shells add about 10-15℉ of warmth to your ride.
Cool-Air Mesh, All-Season Airtex, and Performance Thermal—one armor fits all.
3 Controversial Truths About Motorcycle Gear
Before we dive into the system, let's address a few things the big gear manufacturers might not want you to realize.
1. "All-Season" jackets are usually a myth. A jacket that claims to work in 100℉ and 40℉ usually does both poorly. It is often too hot for summer even with the liner out, and too drafty for winter. The only way to truly handle all seasons is to change your base layer, not just open a zipper vent.
2. You are overpaying for armor. If you own three riding jackets, you likely own three sets of elbow and shoulder pads. Why pay for the same protection three times? It makes more sense to invest in one set of premium, CE-Level 2 armor and move it to where you need it.
3. Your jacket might be comfortable but not safe. Traditional jackets need to be loose enough to move around in. But if your jacket is loose, your armor is loose. In a crash, loose armor shifts. The safest armor is armor that stays snug against your skin, independent of your outer jacket.
How the Modular System Works
The concept is simple: One Armor Set. Multiple Shell.
Most riders start by buying a complete "Kit" (Armor + Fabric Shell). But once you own that armor, you never have to buy it again. You can simply buy our fabric "Shells" for a fraction of the cost of a full garment.
Here is the breakdown of the system:
1. The Core: CE-Level 2 Armor
At the heart of the system is our high-performance viscoelastic foam armor. It is soft and flexible while you ride, but hardens instantly upon impact.
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It covers your back, shoulders, elbows, hips, knees, shins, and more.
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It is designed to last years without degrading.
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It fits perfectly into pockets in all of our shirts and pants.
Complete CE-Level 2 armor set—the core of your modular system.
2. The Shells: Choose Your Climate
We offer three distinct fabric shells. The armor pockets are identical in all of them, so your pads transfer seamlessly.
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The Heat Beater: Cool-Air Mesh Shirt and Pants - Living in Mooresville, NC, we know humidity. Our Cool-Air Mesh is an open-weave fabric that holds the armor tight but lets the wind pass right through to your skin. Pair this with a lightweight jersey or mesh jacket, and it's like air-conditioning for your bike.
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The Daily Driver: All-Season Airtex Shirt and Original Pants - This is our "Goldilocks" fabric. Made from a high-quality mesh and Lycra™, it stretches to fit your body comfortably. The pants feel like comfortable yoga pants or compression wear. It breathes well enough for warm days but offers enough substance for cool mornings. If you are a commuter or touring rider, this is your go-to. We offer this shirt in many colors, but we linked to the black and white one above.
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The Winter Warrior: Performance Thermal Shirt and Pants- When the temperature drops, swap your armor into our Thermal shells. This fabric is brushed on the inside to trap body heat, adding significant warmth without bulk.
The "Invisible Protection" Advantage
The real beauty of the modular system is that it makes your protection invisible.
Because the armor is held close to your body in a low-profile shirt or pant, you can wear almost anything over it.
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Commuting? Wear the armor under khakis and a button-down.
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Cruising? Wear it under your favorite leather jacket and heavy denim.
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Adventure Riding? Wear it under a waterproof shell or MX jersey.
You don't have to look like "RoboCop" when you walk into a restaurant. You can just peel off your outer layer and look like a normal person, all while knowing you have CE-Level 2 protection hugging your vital zones.
Invisible protection—armor worn discreetly under everyday clothing.
Addressing the "Hassle" Factor
I'll be honest: Taking the armor out of one shirt and putting it into another takes about 1 to 1.5 minutes—quick enough that it never feels like a chore. And because the armor is fully removable, washing your gear is just as easy: pull the pads out, toss the shell in the wash, and you're done. That’s something most heavy leather jackets simply can’t offer.
Simple 1-1.5 minute process—remove armor from one shell, insert into another.
What About Abrasion?
This is important: Bohn shells are for impact protection, not abrasion resistance.
We designed them this way to keep them lightweight and breathable. If we lined them with Kevlar®, they would be too hot for summer.
The Solution: Always wear an abrasion-resistant layer over your Bohn armor if you are riding at highway speeds.
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For the slide: Your outer layer (Leather, Kevlar® jeans, heavy textile).
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For the impact: Your Bohn armor underneath.
This "layering" approach is actually safer than a single garment because it allows the outer layer to tear or slide without moving the armor away from your elbow or knee.
We also make jackets, flannels (more colors available), and hoodies that are fully lined with Kevlar®, and built to layer perfectly with Bohn armor.
Smart layering—Bohn armor for impact, outer layer for abrasion resistance.
Frequently Asked Questions
Can I really use the same armor for shirts and pants?
The armor in Bohn gear is limb-specific. You cannot put a knee pad in a shoulder pocket. However, the set of armor you buy for a shirt fits all our shirts (Cool-Air, Airtex, Thermal). The set for pants fits all our standard pants.
Note: Our Adventure Pants use shorter knee pads that are specifically designed for that product and are not interchangeable with the knee pads in our original pants.
How long does the armor last?
Our armor is designed to last up to 10 years before the material begins to degrade. You can crash in it multiple times (as long as the foam isn't torn) because it is viscoelastic—it returns to its shape after impact.
Is it hard to change the armor?
Not at all. The pockets are easily accessible. After you do it once or twice, you can swap a full set of armor in while you're waiting for your coffee to brew.
Watch here:
Do you sell the shells separately?
Yes! That is the whole point of the modular system. On our website, you can choose to purchase each product with "Armor" or "No Armor" options. The "No Armor" option is significantly lower in price than the full kit with armor included.
I'm a plus-size rider. Will this system fit me?
Absolutely. We pride ourselves on sizing. We offer sizes from 3XS to 5XL, including Short, Tall, and Big options. The modular shells are stretchy and forgiving, making them ideal for riders who struggle to fit into stiff, off-the-rack moto gear.
Is the Thermal shell really warm enough?
It makes a huge difference. Our customers tell us it adds about 10-15 degrees of warmth. For deep winter riding, you will still want a windproof outer jacket, but the Thermal base layer does the heavy lifting of retaining your body heat.
Next Step: Check your closet. If you are tired of bulky gear that doesn't fit right, try starting with one Bohn "Kit" and see how it feels to have armor that actually moves with you.
This video is an excellent resource as it walks you through exactly how the armor fits into the garments and highlights the significant weight and comfort advantages of our CE-Level 2 system compared to traditional gear.
