Finding the "best" motorcycle armor can feel overwhelming, can't it? You're sorting through CE ratings, different materials, and jackets that cost a fortune, all while wondering if any of it will be comfortable enough to wear, especially in the summer heat.
Many riders, after spending hundreds on gear, find it's so stiff or hot that they "forget" it on shorter rides. The biggest problem isn't just the armor's rating; it's whether that armor will be in the right place at the exact moment you need it.
My name is Kristen Staggs, and at Bohn Body Armor, we've focused on solving this puzzle for over 25 years.
Finding armor that fits, stays in place, and is comfortable especially in summer is tough. Bohn solves this with 25+ years of expertise.
If you're looking for a comfortable, reliable system that you'll actually wear, here are my top recommendations.
Top Motorcycle Armor Recommendations
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Best for Hot Weather: Bohn Body Armor Cool Air Armored Shirt and Pants. These aren’t a jacket and pants; they are breathable mesh base layers with CE-Level 2 armor protection. Designed to be worn under any jacket (or even shirt) and pants, they give you maximum airflow while keeping armor locked in place.
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Best for All Seasons: Bohn Body Armor Airtex Shirt and Original Lycra™ Pants. These use a soft, stretchy Lycra™ fabric to hold CE-Level 2 armor at the hips, knees, and shins, plus pads for the tailbone and thighs. You wear them under your favorite jeans or riding pants, giving you comprehensive impact coverage that moves with you.
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Best for Cold Weather: Bohn Body Armor Performance Thermal Shirt and Pants. These use a thicker thermal layer to add 10-15 F to your ride, ideal for holding in heat on cold shoulder-season rides. Available for our pants and shirts, and easy to layer with other outerwear shells or rain shells.
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Best for Abrasion Resistance: Bohn Body Armor Kevlar® Jacket, Hoodie, or Flannel. Layering one of our fully Kevlar®-lined pieces over Bohn’s base layers gives you abrasion protection all around with snug-fitting impact protection underneath. The best of both worlds. For pants, we recommend Kevlar® jeans or just a normal pair of sturdy jeans.
Bohn modular armor fits all seasons: Cool Air, Airtex/Lycra™, Thermal, and Kevlar® layers for lightweight, full CE-Level 2 protection.
You can also buy one set of armor and multiple sets of the above Bohn fabrics for the best all-season coverage at a much lower price than buying dedicated gear for each season. And, many of our pants and shirts have an adventure option with chest armor (for the shirts) and shorter knee pads (for the pants to fit into tall off-road boots).
Bohn armor is perfect for all types of riders:
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T-Shirt and Shorts Guy: Traditional gear is too hot/cumbersome or not your style, but you know you should wear it. Pick up Bohn’s Cool Air Armored Shirt and Pants for high quality impact protection without excess weight or discomfort.
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ATGATT Maximizer: You always wear the gear, all the time, but you’re concerned the armor won’t stay put in a crash (especially with looser ADV gear). You’re not alone, and Bohn’s Airtex Shirt and Original Lycra Pants can replace the armor in your outerwear for a safer and more comfortable fit. Plus, we have adventure options, including chest armor in the shirts and shorter knee armor to accommodate tall adventure boots. Layer your Klim, Mosko, or whatever over top!
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Small, Large, Big, Tall Sizing: Traditional motorcycle gear often fails to fit most riders well, because our bodies aren’t all the same shape and size, and within 2 sizes of each other. Bohn’s stretchy material fits riders of all shapes and sizes, and our sizing ranges from 3XS to 5XL with Big, Tall, and Short options!
Before we get into the details, I want to share a few things we've learned in our 25+ years in this business. These might sound controversial, but they are critical to understanding how to stay safer on two wheels.
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The armor in your expensive armored jacket might not be where you think it is when you actually crash. The best armor works because it stays put.
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“Dress for the slide, not the ride” is actually incomplete advice. While abrasion resistance is necessary for high-speed slides, breaking bones due to impact is typically far more life-altering, painful, and expensive to fix than road rash. More on this below.
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Most armored underlayers from European brands are not designed for US heat and humidity. Brands like Pando Moto, Bowtex, and Knox often make great products, but they are generally built for milder European climates. In the sweltering heat and high humidity of the US, riders often find these garments too warm, which leads them to either ride in discomfort or skip wearing gear altogether and that’s a protection fail.
Let's talk about why.
The Great Debate: "Dress for the Slide" vs. "Dress for the Impact"
You’ve heard it a million times: "Dress for the slide, not the ride." It's the classic adage focused on preventing road rash. Abrasion resistance is absolutely important, especially for high-speed highway or track riding, where long slides can happen.
But what about the impact?
In our experience, and from what thousands of customers have told us, most everyday street crashes are not 100-mph slides. They are low-sides, t-bones, and tumbles. They involve hitting the ground, a car, or a curb. In these scenarios, the force of that impact is what causes the worst injuries.
Road rash heals. A shattered hip, a broken femur, or a damaged spine can change your life.
Bohn focuses on impact first armor key zones to prevent serious injury, letting you pair your favorite abrasion layer on top.
This is why we believe in dressing for the impact first.
This is the entire philosophy behind our armored base layers. We focus on putting the best impact protection in all the key places and then encourage you to wear your favorite abrasion-resistant layer over it. That could be a leather jacket, a mesh shell, or one of our fully Kevlar®-lined flannels or jackets.
Why "Armor That Stays Put" is the Most Important Feature
Here's the problem with most all-in-one armored jackets and pants: they are, by nature, a compromise.
To be comfortable, they have to have some room. But that room is the enemy of protection. In the chaos of a crash, a loose jacket can twist. That CE-Level 2 elbow pad you paid for? It's now protecting your bicep, leaving your joint exposed when it hits the pavement.
Armor only works if it's in the right place at the right time.
Bohn’s body-close fit keeps CE-Level 2 armor exactly where it belongs, unlike loose all-in-one gear that shifts in a crash.
This is where Bohn's body-close fit is so important. Our armored shirts, pants, and shorts are made from stretch fabrics like Lycra™ and mesh. They are designed to fit snugly, like a second skin.
This does two things:
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It's incredibly comfortable and less restrictive than bulky traditional gear.
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It locks the armor directly against your body, so it cannot move or shift.
Whether you're reaching for the handlebars or tumbling in a crash, that armor is exactly where we designed it to be. Our customers have confirmed this for us time and time again over the last two decades.
Understanding CE-Levels (And What They Miss)
You'll see "CE-Level 1" and "CE-Level 2" on almost all modern armor. What's the difference?
In simple terms, it's a measure of how much protective force is transferred through the armor to your body in a standardized test.
The European Conformity (CE) rating is a commonly applied set of standards for motorcycle safety gear. For armor and impact protection, we have just two ratings:
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CE-Level 1 armor is rigorously tested, allowing a maximum transmitted force of 18 kilonewtons (kN) or less, with no single value exceeding 24 kN. It's typically thinner and more flexible, making it great for urban or casual riding. Even some high-end, expensive motorcycle gear comes only with CE-Level 1 armor.
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CE-Level 2 is the top level of protection available. It must transmit a maximum force of 9 kN or less, with no single value exceeding 12 kN. This means it absorbs significantly more energy often up to 50% more than Level 1 making it ideal for high-speed, touring, or track riding.
All the armor in Bohn shirts (back, chest, shoulders, elbows/forearms) is CE-Level 2. In our pants, the key impact zones hips, knees, and shins are also CE-Level 2. The armor itself is a high-quality viscoelastic foam that is designed to last 10 years and can even be reused after a crash.
But the CE rating isn't the whole story. What the rating doesn't tell you is the coverage area or extra protection areas.
A tiny, stamp-sized piece of CE-Level 2 armor isn't going to do you much good. This is another area where we decided to be different. Bohn has some of the largest impact protectors in the industry.
Our elbow/forearm protector, for example, is a single piece measuring 5 inches by 12 inches. Our knee/shin piece is the same. Our pants and shorts include coverage for the hips (femur joint), thighs, and tailbone areas often ignored by other gear.
Bohn CE-Level 2 armor absorbs more impact with oversized protectors, covering elbows, forearms, knees, shins, hips, and tailbone.
As for extra protection, our thigh and tailbone armor is not CE rated – because the CE standard does not certify thigh and tailbone armor. As a result, most manufacturers simply don’t include it, because there’s no extra benefit to the ratings they can claim. Bohn includes this extra armor, because we care about your safety more than we do ratings.
More coverage, held in the right place, means a better chance of mitigating injury. That’s our goal.
Solving the "It's Too Hot to Wear Gear" Problem
Let's be honest. Riding on a 95°F day with 90% humidity is brutal. This is when we see riders in t-shirts and jeans, and frankly, we get it. Traditional gear is hot.
Many "abrasion-resistant" underlayers from other brands are made with thick, woven materials designed for milder European climates. They are simply too hot for most of the U.S. in the summer.
This is why we developed our Cool Air mesh fabrics. These are true, open-mesh base layers that are lightweight and wick sweat away from your body. They are designed to maximize airflow.
COOL AIR MESH PRODUCT BOXES
You can wear a Bohn Cool Air Armored Shirt under a non-armored mesh jacket, or even just under a regular shirt, and get incredible airflow plus full CE-Level 2 impact protection. It's meaningful protection you will actually be comfortable wearing, which is the whole point.
Bohn Cool Air mesh keeps you cool and protected, letting you ride comfortably in hot, humid weather without sacrificing CE-Level 2 armor.
And for those who ride in the cold, we have Performance Thermal options that add about 10-15°F of warmth to your ride.
Solving the "Gear Never Fits Me" Problem
The "one-size-fits-most" model of traditional motorcycle gear leaves a lot of riders behind. If you're tall and lanky, plus-size, have a "beer belly," or are a petite woman, finding gear that fits is a nightmare. When it doesn't fit, the armor is in the wrong place.
We've made fit a priority from day one. Because our gear is designed to stretch and conform to your body, we can comfortably fit a much wider range of people.
Our sizing runs from 3XS all the way up to 5XL, with specific Short, Tall, and Big options available for many products. We have patterns that fit riders from 4'9" all the way up to 6'10". Our size chart is extremely accurate, and if you still don't see your size, you can contact us for custom-made options.
Bohn gear stretches and conforms to fit riders from 3XS to 5XL, including Short, Tall, and custom options for all body types.
This isn't just about comfort; it's about safety. A proper fit is what keeps the armor where it belongs.
The Bohn System: Impact + Your Choice of Abrasion
So, let's put it all together. How do you use Bohn armor?
Our armored shirts and pants are not abrasion-resistant by design. This is what makes them so light, breathable, and comfortable.
You pair them with an abrasion layer of your choice. This modular system is more versatile, more comfortable, and often more affordable than buying multiple all-in-one outfits.
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For Cruising: Wear our armored pants under your favorite heavy denim or leather chaps. Our customers report that with a good pair of jeans over their Bohn armor, they see fantastic results in a crash. Pair an armored shirt with our fully Kevlar®-lined Flannel or Jacket.
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For Adventure/Dual-Sport: Wear our shirt and pants under a lightweight, non-armored mesh shell. You get full protection without the bulk or heat. (We even make an "Adventure" pant with shorter shin armor to fit better in tall off-road boots).
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For Casual Rides: Wear our armored pants under your jeans and the armored shirt under a regular sweatshirt. It's invisible protection that is far, far better than nothing.
The "best" motorcycle armor is the armor you are comfortable wearing on every single ride. It's armor that fits you perfectly. And most importantly, it's armor that will be exactly where it needs to be if that terrible moment ever comes.
Bohn modular armor can be worn alone or paired with any outer layer, giving lightweight, all-day protection that stays put on every ride in all conditions.
And the best part is Bohn is more affordable than traditional motorcycle gear. With one set of armor and multiple sets of fabrics for different seasons, you can ride safely in all conditions. The armor itself has a lifespan of about 10 years, so if you treat the fabrics well, that’s about $40-60 a year for protection. That’s cheaper than insurance!
Stay safe out there.
Frequently Asked Questions About Motorcycle Armor
What is the difference between CE-Level 1 and CE-Level 2 armor?
CE-Level 2 is the higher, more protective standard. In a lab test, it allows less than half the force of an impact to be transmitted to the rider's body compared to CE-Level 1 armor. All Bohn shirts use CE-Level 2 armor , as do the main impact zones in our pants.
Is D3O armor the best?
D3O is a very popular brand of "non-Newtonian" armor, and it's excellent. Bohn uses a top-tier viscoelastic foam that performs similarly. It's soft and flexible during normal riding, then hardens instantly upon impact. Our armor is also rated CE-Level 2, is designed to last for 10 years, and the main difference––it’s reusable even after a crash.
Can I really wear Bohn armored pants under my regular jeans?
Yes, that's exactly what they're designed for. The Lycra™ or mesh fabric is thin and fits snugly, so it slides easily under denim, leather, or textile pants. For slide protection, we recommend wearing them under heavier-weight motorcycle-specific denim or leathers.
How do I wash Bohn armored clothing?
It's simple. All the armor pads are easily removable from the interior pockets. Once you remove the pads, you can machine wash the shirt or pants and hang them to dry.
Is Bohn armor good for hot-weather riding?
It's our specialty. Our Cool Air mesh shirts and pants are made from a highly breathable mesh, designed for maximum airflow. They help wick sweat and are far cooler than traditional jackets or abrasion-resistant base layers.
What if I'm in between sizes on your size chart?
Our size chart is very accurate if you follow the measuring instructions. Because the fabric is stretchy, it has some flexibility, but a snug fit is key to keeping the armor in place. If you're right on the line, we generally recommend sizing down for that secure, body-hugging fit. You can always call us for a personal recommendation.
Does Bohn armor work well for women?
Absolutely. We've designed our patterns to be size-inclusive and fit all body types, not just a "standard" male build. We offer a huge range of sizes, including options for petite women, and the stretch fabric helps conform to different body shapes.
How long does Bohn armor last?
The fabric garments are designed to last for years. The viscoelastic armor pads are extremely durable, designed to last 10 years before their impact-absorbing properties begin to degrade. And unlike some armor, they are multi-impact capable, meaning they are still effective after you've used them in a crash.
