When a British motorcycle racer moved to Northern California in the mid-1990s, he couldn't believe what he saw on American roads. Riders everywhere were cruising in nothing but jeans and T-shirts, treating 110-degree summer heat as a valid excuse to skip protection entirely. That cultural shock – combined with his racing background and the brutal reality of California summers – sparked a solution that's been protecting riders since 1997.
Most riders think they have two choices: sweat through full leathers or risk everything in street clothes. That false choice has led to countless preventable injuries over the decades. The relief comes when you realize there's been a third option hiding in plain sight for 28 years.
This is the story of how one rider's frustration with impractical gear created an entire category of motorcycle protection.
Invisible Protection, From the Beginning
From the beginning, Bohn set out to solve a simple problem: most protective gear wasn’t being worn because it was bulky, uncomfortable, or restrictive. Our early approach focused on moving armor closer to the body and designing it to disappear under everyday riding clothes.
As the brand evolved, that original concept expanded into a range of base-layer protection for both upper and lower body use. Lightweight materials, flexible construction, and careful sizing allowed armor to stay in place without limiting movement or forcing riders to change how they dressed.
Bohn was built on a simple idea: armor works best when it fits close, stays comfortable, and gets worn on every ride.
What connects all of Bohn’s designs is a consistent focus on fit, comfort, and real use rather than trends or hype. By keeping armor low-profile and body-hugging, Bohn made everyday protection more accessible for riders who value both safety and wearability.
Four Truths About Motorcycle Armor History Most Riders Don't Know
American riders didn't always skip protection – they just never had practical options. Before 1997, you either wore full racing leathers or nothing at all. There wasn't a middle ground that worked for everyday riding in different temperatures.
The "base layer armor" concept wasn't invented for comfort – it was invented out of necessity. Paul English literally couldn't ride in Northern California summers wearing traditional gear. The Bodyguard System™ was his solution to a problem that was keeping him off his bike.
Base layer armor wasn’t about comfort – it was survival. Paul English built the Bodyguard System™ so summer heat wouldn’t stop the ride.
Most motorcycle armor you see today has a 10 year expiration date, but riders rarely replace it. That armor in your 8-year-old jacket? It's probably crumbling and offering minimal protection. Bohn made replacement armor a core part of their business model specifically to address this ignored safety issue.
The company that pioneered invisible protection is still family-owned and American-made. While most motorcycle gear companies outsourced everything overseas, Bohn's BodyGuard System is still sewn in the United States, now under the ownership of myself (Kristen) and Ed Staggs who took over in 2017.
The British Racer Who Thought Americans Were Crazy
Paul English grew up in the UK racing motorcycles at the highest levels. He competed at the Isle of Man, one of the most dangerous road races in the world. For him, protective gear wasn't optional – it was survival equipment.
When he moved to America in the mid-1990s, the sight of riders in T-shirts shocked him. These weren't just casual cruisers – he saw sport bike riders, touring riders, all types exposing themselves to serious injury. It seemed absolutely nuts to someone who'd spent his life suited up in full leathers.
From Isle of Man to 110°F California, Paul English saw why riders skipped gear – and built protection you can actually wear!
Then his first California summer hit. Temperatures climbed past 110 degrees Fahrenheit for weeks at a time. Suddenly Paul understood why American riders weren't wearing traditional protection – it was legitimately unbearable in that heat.
The Problem That Created a Solution
Paul faced a dilemma. He loved riding his motorcycle, but he refused to ride unprotected. Yet wearing full leathers or even most motorcycle jackets in 110-degree heat wasn't sustainable – it was miserable and potentially dangerous from heat exhaustion.
Traditional motorcycle jackets of that era were designed for track racing or cooler climates. They offered no solution for riders who needed protection during daily commutes, weekend rides, or any riding that didn't justify full racing gear. The market had a massive gap.
Paul solved riding’s biggest problem: real protection in extreme heat. The Bodyguard System™ lets you ride armored under normal clothes.
That's when Paul invented the Bohn Bodyguard System™. His concept was radically simple: create armored shirts and pants that fit snugly against your body, protecting the most vulnerable impact areas (shoulders, elbows, back, hips, knees, tailbone), but designed to be worn under regular clothes. You could throw on your favorite jeans and a shirt, with CE-certified armor hidden underneath.
Building a Company on a Simple Premise
Bohn Body Armor officially launched in 1997 with that core concept. The company's name came from Paul's belief that armor should feel like a second skin – protection that moves with you rather than restricting you. The goal wasn't to replace traditional motorcycle jackets but to provide an option for riders who wouldn't otherwise wear any protection at all.
The early products used Lycra™ and mesh fabrics to create form-fitting base layers. Pockets were strategically placed to hold armor over the shoulders, elbows, back, hips, knees, shins, thighs, and tailbone. The armor stayed in place during riding because the garments fit snugly – no shifting, no gaps in coverage.
Born in 1997, Bohn created invisible armor that moves like skin – real protection riders actually wear, all day, every ride.
What made Bohn different was the focus on comfort and wearability. Paul understood that protection riders won't wear is useless. If the gear was uncomfortable, bulky, or obvious under street clothes, riders would leave it at home. His products were designed to be invisible protection – something you could wear all day without thinking about it.
From California to North Carolina: The Ownership Transition
Paul English ran Bohn Body Armor for 20 years, building it into the leading brand for base layer motorcycle protection. He established the company's reputation for quality, comfort, and American manufacturing. Sadly, Paul passed away in 2016 but his vision lived on.
In 2017, myself (Kristen) and Ed Staggs purchased Bohn Body Armor. Both of us brought deep motorcycle industry experience – Ed had raced motocross for over 20 years in Southern California during the 70s, 80s, and 90s, then worked at Fox Racing and a Harley-Davidson dealership. I had spent years at Harley-Davidson in New England.
Bohn Body Armor thrived for 20 years under Paul English. Today, under Kristen & Ed Staggs in NC, it continues delivering quality, comfort, and ride-ready protection.
We (the Staggs) made a strategic decision to move the company to Mooresville, North Carolina, just north of Charlotte. This move put us in the heart of NASCAR country but also gave us better manufacturing infrastructure and logistics. We opened a small showroom so riders can visit, try on gear, get custom fittings, and share riding stories.
Expanding the Vision: Inclusivity and American Manufacturing
Ed and I didn't just maintain Paul's legacy – we expanded it. In 2021, we recognized that Bohn's sizing didn't serve everyone who needed protection. We completely redesigned our patterns to accommodate Big+Tall, Petite, Short, and Youth sizes.
Now Bohn offers protection for riders from 4'9" to 6'10" tall, in sizes from 3XS to 5XL. This wasn't a minor adjustment – it required retooling our entire production process. But it aligned with our focus on helping women and underserved riders get the protection they deserve.
In 2021, Bohn expanded to fit riders 4'9"-6'10", prioritizing real comfort, durability, and protection over trends – gear built for every rider.
We have consistently focused on building gear the right way, prioritizing durability, materials, and rider needs over trends or marketing hype. Rather than designing products to satisfy rating agencies or chase headlines, Bohn focuses on how armor actually fits, feels, and performs in everyday riding. Headquartered in the United States and American-owned and operated, Bohn continues to source the best materials available and design gear with long-term protection and rider comfort as the top priority.
The Reality of Wearing Base Layer Armor
Here's what riding with Bohn gear actually feels like. You put on the armored shirt or pants like regular athletic wear. The material is soft and stretches, so it's not restrictive. The armor pockets hold SAS-TEC protectors against your shoulders, elbows, back, hips, knees, and tailbone.
Then you put your regular clothes over top. Jeans go on normally (the pants fit underneath without bunching). Your favorite shirt, flannel, or hoodie covers the armored shirt completely. From the outside, you look like any other rider in street clothes.
The armor does add a layer, so you'll feel slightly warmer than riding in just a T–shirt. But it's dramatically cooler than wearing a traditional motorcycle jacket – especially in mesh or Cool Air versions. On hot days, many riders find the base layer actually helps with moisture wicking.
Addressing the Limitations Honestly
Bohn armor does not provide abrasion protection. The mesh fabric can show some wear over time, but the armor stays in place and doesn't tear free from the garment. If you're sliding down pavement, the base layer won't save your skin – that's what abrasion resistant jeans or riding pants are for.
Think of Bohn as impact protection, not crash armor. It helps prevent injuries to your joints, spine, and hips from striking objects or the ground. For complete protection, you'd wear Bohn under abrasion-resistant pants and a jacket.
The snug fit also takes getting used to. Some riders feel constricted at first, especially if they're not used to compression-style athletic wear. But the tradeoff is armor that actually stays where it belongs during a crash.
Finally, armor has a lifespan. SAS-TEC protectors last 10 years from manufacture. If your armor is crumbling or cracking, it needs replacing. Bohn makes this easy by selling replacement armor separately – you don't need to buy entirely new garments.
The Legacy of "Dressing for the Impact"
Twenty-seven years after Paul English created the first Bodyguard System™, his core insight remains valid. Riders need protection that fits their real lives – not just their track days or long tours. The vast majority of motorcycle crashes happen during normal riding: commuting, running errands, weekend rides.
Traditional gear companies tell riders to suit up like they're racing the Isle of Man every time they ride. That's not realistic for most people. Bohn's approach acknowledges reality: give riders practical protection they'll actually wear consistently.
The phrase “dress for the slide, not the ride” is common in motorcycle safety circles, but Bohn recognized a missing piece: riders won’t wear protective gear if it’s bulky, uncomfortable, or doesn’t fit properly. By focusing on body-hugging, flexible base layers that move naturally with the rider, Bohn makes it easier for riders to wear protection every time they ride – not just on long trips.
Why This History Matters to Riders Today
Understanding Bohn's history helps you appreciate what you're buying. This isn't some drop-shipped gear from a faceless company. It's a family-owned American business with deep roots in motorcycle racing and a genuine commitment to rider safety.
When you put on Bohn armor, you're wearing the solution to a problem that stumped the industry for decades. You're benefiting from Paul English's racing experience, his engineering ingenuity, and his refusal to accept that riders had to choose between comfort and protection.
You're also supporting our vision of inclusive, American-made motorcycle gear. Their work expanding sizing, upgrading armor technology, and maintaining domestic ownership continues Paul's legacy while adapting to modern riders' needs.
Frequently Asked Questions
How long has Bohn Body Armor been in business?
Bohn was founded in 1997 by Paul English, making the company 28 years old. Current owners Kristen and Ed Staggs took over in 2017. The company has been serving riders continuously for over a quarter century with the same core product philosophy.
What happened to Paul English, the founder?
Paul English founded Bohn Body Armor and ran it for 20 years until 2017. He has since passed away, but his vision for comfortable, invisible motorcycle protection continues under new ownership. The Bodyguard System™ he invented remains the foundation of all Bohn products.
Where is Bohn Body Armor manufactured?
Bohn's BodyGuard System (Lycra™ and mesh pants, shorts, and shirts) is sewn in the United States. The company is headquartered in Mooresville, North Carolina. The SAS-TEC armor inserts are manufactured in Germany by their partner company, which is designed in the USA.
Why did Bohn switch to SAS-TEC armor?
We partnered with SAS-TEC to offer CE-Level 2 certified protection that exceeds minimum certification requirements by 30-40%. SAS-TEC armor is recyclable, multi-impact rated, and represents the latest in protection technology. This partnership improved Bohn's protection significantly while maintaining American manufacturing for the garments.
Do I need to replace my Bohn armor, and how often?
Yes, armor has a lifespan of 10 years from manufacture, similar to motorcycle helmets. If your armor is crumbling, cracking, or more than 10 years old, it needs replacement. Bohn sells replacement SAS-TEC armor separately so you don't need to buy new garments – just swap in fresh protectors.
Can I wear Bohn armor under regular jeans and street clothes?
Absolutely – that's exactly what it's designed for. Paul English created the Bodyguard System™ specifically to be worn under normal clothes. The armor provides CE-Level 2 protection while remaining invisible under jeans, pants, shirts, and jackets. This is Bohn's core value proposition: protection you'll actually wear because it doesn't force you to look like you're dressed for the track.
Does Bohn offer sizes for shorter or taller riders?
Yes. In 2021, Bohn expanded their sizing to include Big+Tall, Short, and Petite options. We now fit riders from 4'9" to 6'10" tall in sizes ranging from 3XS to 5XL. This expansion was a priority for us, particularly to serve women and previously underserved riders.
How is Bohn different from other motorcycle armor brands?
Bohn pioneered the base layer armor concept in 1997 – protection designed to be worn under street clothes rather than as outerwear. We offer the widest selection of CE-Level 2 SAS-TEC armor in the US, and focus on practical everyday protection rather than just track-oriented gear. Our 28-year history demonstrates lasting commitment to this specific niche.
