Best Mesh Motorcycle Jackets that Stay Cool in Summer
Staying cool during a mid-summer ride is something every rider thinks about once the temperature hits 85℉. At Bohn, we have been helping riders beat the heat since 1997 by focusing on gear that actually lets the air through to your skin. Many riders think they have to choose between being safe and being comfortable, but we have spent over 25 years proving that you can have both.
If you pick a jacket that doesn't breathe well, you end up sweaty, tired, and losing your focus on the road. The relief of finding a setup that feels like you are wearing a t-shirt while still having impact protection in place eliminates the sweat-fest that can ruin an otherwise great summer ride.
You can finally stop dreading the red lights and start enjoying the wind without worrying about whether your armor will stay put if you trip.
This guide will show you how to find a mesh jacket that actually works for your body type and your riding style. We will also share how Bohn approaches summer riding differently – by opting for breathable layers instead of a single “do-it-all” jacket.
Bohn Body Armor Airtex motorcycle shirt offers a great balance between comfortable material, high airflow, and all-weather wearability.
Why Standard Mesh Jackets Often Fail
Most mesh jackets you find in stores are built as a "one-size-fits-all" solution that tries to do too much. They are often made with thick, heavy mesh that doesn't actually flow air as well as it looks like it should. Because they want to look like "real" jackets, they add extra pockets, heavy zippers, and thick collars that trap heat right against your neck and chest.
Another common problem is that these jackets are often cut very large to accommodate different body shapes. This means the elbow pads might be dangling three inches below your actual elbow. When you are riding at 60 miles per hour, that extra fabric flaps in the wind, which is noisy and exhausting for a long day in the saddle.
Most mesh jackets trap heat and flap in the wind. Bohn flips the script: body-fitted armor base layers for real airflow and comfort.
At Bohn, we approach this differently. We believe the armor should be a base layer that fits your body perfectly, and your "jacket" should just be an outer shell for style or abrasion resistance. This way, you get the best possible airflow without the bulk of a traditional heavy jacket.
The Bohn Base Layer Solution
Bohn’s mesh base layer approach eliminates the drawbacks of a traditional jacket by placing CE-Level 2 SAS-TEC armor directly against your body in an ultra-breathable mesh garment. Instead of a $300 mesh jacket with loose armor, you wear a Bohn Cool-Air Armored Shirt that’s almost entirely open mesh.
Over it, you can add any outer layer – a light windbreaker, a denim shirt, or nothing for low-speed riding. Or a CE approved, highly-abrasion resistant motorcycle jacket from one of the brands we’ll talk about below.
This system provides maximum airflow because there are no thick zippers, collar sections, or solid panels blocking the breeze, and the armor never shifts because it's held against your joints by stretchy Lycra™ fabric.
You can even soak the mesh shirt in water for evaporative cooling, a trick that's near impossible with traditional mesh jackets.
Mesh base layer with CE armor locked to your body. Maximum airflow, soakable for evaporative cooling. Traditional jackets can't match.
While modern mesh motorcycle jackets still compromise between structure and ventilation, Bohn's base layer system remains the only approach that delivers true maximum airflow while keeping protection locked in place.
This is why riders who try both systems choose the base layer approach for serious hot weather riding.
Top Recommendations for Hot Weather Riders
Bohn Cool-Air Armored Shirt
This is our lightest and most breathable option, specifically designed for those days when the humidity makes you want to leave your gear at home. It uses a very open mesh fabric that lets every bit of breeze reach your skin while keeping your SAS-TEC armor exactly where it needs to be. It is so slim that you can wear it under a light long-sleeve shirt or a thin windbreaker and no one will even know you are wearing gear.
Bohn Airtex Armored Shirt
For riders who want a bit more structure but still need a lot of airflow, the Airtex is our classic choice that works in almost any climate. It features a mix of Lycra™ and mesh to give you a snug, "second-skin" fit that prevents the armor from moving around. This is the perfect choice for a daily commuter who wants to stay cool during the ride and then easily peel off their outer layer once they get to the office.
Get the AirTex™ Shirt with Lycra™
Bohn Armored Mesh Pants
You shouldn't forget about your lower body – most riding injuries are to the legs. These pants are made entirely of our breathable mesh and feature SAS-TEC CE-Level 2 armor for your hips, knees, shins, thighs, and tailbone. They fit right under your favorite pair of jeans or work pants, giving you invisible protection that won't make your legs feel like they are in an oven.
The Secret to Staying Cool in Humidity
If you ride in places like the Southeast or the Midwest, you know that humidity changes everything. Standard mesh fabric can sometimes feel like a plastic bag once the air gets thick with moisture. This is where materials like Lycra™ and our specialized open-cell mesh make a huge difference.
These fabrics are designed to wick moisture away from your skin. As the wind passes through the mesh, it evaporates that moisture, which creates a natural cooling effect. It is the same science behind high-end athletic gear, but we have added CE-certified armor to the mix.
Bohn Cool Air ultra-breathable mesh fabric allows maximum airflow for moisture wicking in humid conditions
If you find yourself in extreme heat, you can even soak your Bohn shirt in cool water before you put it on. The airflow through the mesh will act like a personal air conditioner for the first 30 to 45 minutes of your ride. This is a simple trick that many of our long-distance touring riders use to cross the desert in the summer.
Impact Protection That Doesn't Feel Like Plastic
A big reason riders skip their gear in the summer is that the armor feels like a hot piece of plastic taped to their skin. Standard foam or hard plastic pads don't breathe at all. This creates "hot spots" on your elbows and back that can become very itchy and irritating after an hour.
We use SAS-TEC armor in all of our garments because it is a viscoelastic foam. This means it is soft and flexible while you are moving, but it disperses impacts if hit hard. It also features ventilation holes throughout the pads to let heat escape from your joints.
Bohn 5x12 inch SAS-TEC elbow and forearm armor provides maximum coverage in low-profile thin design
Our armor is also low-profile. Our elbow and forearm pads are a generous 5 × 12 inches, but they are thin enough to disappear under a regular shirt. The shoulder pads come in two sizes: 5 × 8 inches for standard sizes and 6 × 9 inches for our 3XL to 5XL riders. You get massive coverage without the "football player" look.
Impact vs. Abrasion
Riders often ask if a mesh shirt is "enough" protection. The truth is that our shirts are simply not designed for abrasion resistance; they are designed for impact protection. In a fall, the first thing that happens is you hit the ground hard. Our SAS-TEC CE-Level 2 armor is there to soak up that energy.
The silver lining here is that because our gear is so slim, you can choose the right abrasion layer for your specific ride and wear it over time. If you are just riding around town at low speeds, a heavy denim shirt over your Bohn gear might be all you need. If you are hitting the highway, you can slide a leather or heavy textile shell over the top.
Bohn mesh armored base layer under light outer shell maintains airflow while adding abrasion protection
By separating the impact protection (Bohn) from the abrasion protection (your outer shell), you have more control over your temperature. On the hottest days, you can wear a very thin outer layer and let the air flow through both layers. It is a modular system that adapts to you, rather than forcing you to adapt to the gear.
So let’s explore some of the best mesh motorcycle jackets on the market today, to give you that outer shell over your Bohn protection.
The Best Mesh Motorcycle Jackets
Below, we'll show you how mesh jackets from leading brands can work as outer shells over Bohn armored base layers. When you choose a loose-fitting mesh jacket for abrasion resistance and pair it with a body-fitted Bohn layer for impact protection, you get the best of both systems.
Alpinestars
Alpinestars brings decades of sport riding experience to their mesh jacket lineup, with excellent ventilation engineering and proven durability. The Alpinestars T-GP Plus R v4 Air Jacket or the Viper v3 Air Jacket are excellent choices to pair with Bohn. These jackets offer a relaxed yet sporty fit with generous room in the shoulders and chest to accommodate an underlayer.
This jacket works perfectly as an outer shell over your Bohn Cool-Air Armored Shirt. Wear your Bohn layer underneath to handle impact protection with SAS-TEC CE-Level 2 armor, then use the Alpinestars jacket for abrasion resistance and reflective visibility features.
Pair Bohn armor with Alpinestars mesh jackets for impact protection, abrasion resistance, airflow, storage, and visibility.
The key is understanding that your Bohn layer is doing the critical job of keeping armor locked against your joints, while the Alpinestars jacket adds the slide protection and practical features you need for street riding.
Rev'It
Rev'It brings European design sensibility to mesh jackets, with excellent build quality and attention to detail. The Rev'It Airwave 4 in the $200-$300 range serves as an ideal abrasion-resistant shell when paired with Bohn armor underneath, with a touring-oriented fit designed to accommodate layers comfortably.
Choose this jacket's relaxed adventure cut to ensure comfortable room for your Bohn Airtex or Cool-Air Armored Shirt. You get Rev'It's quality materials, multiple adjustment points for fit, and weather-resistant features, while your Bohn layer underneath ensures your armor stays exactly where it needs to be during an impact.
Rev’It mesh jackets pair perfectly with Bohn armor–European style, great airflow, touring comfort, and abrasion protection.
The touring-oriented fit means you won't feel compressed or restricted with both layers, and the mesh construction maintains excellent airflow. Pair it with Bohn's body-fitted armor system and you get the best of both worlds: European styling and craftsmanship on the outside, proven impact protection on the inside.
Joe Rocket
Joe Rocket makes mesh jackets accessible for riders on a budget. The Joe Rocket Velocity 2 and Joe Rocket Cleo Elite (for women) are standout choices now. These jackets use Joe Rocket's "FreeAir™" mesh, which flows a massive amount of air, but like many budget-friendly jackets, the internal armor can sometimes feel a bit basic or shift around in the generous, relaxed "American" cut.
Use a Joe Rocket mesh jacket as your abrasion layer over a Bohn Cool-Air Armored Shirt, and you'll have a total investment of around $300-$400 for complete impact and slide protection. Joe Rocket's relaxed fits accommodate the Bohn layer easily, and you get basic features like pockets and reflective trim without breaking the bank.
This combination is perfect for commuters or new riders who want real protection without premium prices. Your Bohn base layer handles the critical armor placement and impact protection, while the Joe Rocket jacket adds the slide resistance for everyday riding.
Scorpion
Scorpion delivers solid mid-range mesh jackets that balance features and affordability. The Scorpion Cargo Air Jacket works perfectly as an outer shell over Bohn armor, with a comfortable touring fit and excellent mesh coverage for airflow.
This jacket serves as your abrasion-resistant layer while your Bohn Cool-Air or Airtex Armored Shirt underneath handles the impact protection. You get Scorpion's quality construction, multiple pockets for storage, and good ventilation, all while maintaining the body-fitted armor placement that only a Bohn base layer can provide.
Scorpion mesh jackets pair with Bohn armor for affordable airflow, touring comfort, abrasion resistance, and locked-in impact protection.
The combination gives you a complete system at a mid-range price point–better materials than budget brands, with the armor security and cooling efficiency that comes from Bohn's specialized base layer design.
Dainese
Dainese represents premium Italian craftsmanship in motorcycle gear. The Dainese Air Frame jacket features a relaxed touring design with sophisticated ventilation that works beautifully as an outer shell over Bohn armor.
Wear your Bohn Cool-Air Armored Shirt underneath for body-fitted SAS-TEC CE-Level 2 armor, then add the Air Frame for premium abrasion resistance, weather protection features, and Italian design. The touring-oriented fit provides ample room for the base layer without feeling bulky, and the fine mesh construction maintains excellent airflow through both layers.
Dainese Air-Frame D1 over Bohn armor delivers Italian style, airflow, touring comfort, and premium abrasion protection.
This is the premium approach to the layering system: Bohn's proven armor technology underneath, with Dainese's craftsmanship and style on the outside. You get maximum protection, maximum cooling, and maximum confidence in your gear.
Frequently Asked Questions
How tight should a mesh armored shirt fit?
Your Bohn shirt should fit snugly, much like a compression shirt or a base layer you would wear for sports. It should not be so tight that it restricts your breathing, but it needs to be close enough to the skin to keep the SAS-TEC armor from sliding around on your elbows and shoulders.
Can I wear a Bohn armored shirt as my only layer?
While you can wear it alone, we generally recommend wearing a thin outer layer over it. The shirt is designed for impact protection, but adding a layer of denim or a light jacket will help mitigate damage from a slide. It also helps protect the mesh from snagging on things.
Is CE-Level 2 armor too heavy for summer?
Not with SAS-TEC. This material is much lighter and more flexible than traditional hard armor. Because it is ventilated, it doesn't trap as much heat as you might expect, and the safety benefits of Level 2 over Level 1 are worth the very small difference in weight.
What is the best way to wash mesh motorcycle gear?
You should always remove the armor pads first. The fabric part of our shirts and pants can be machine washed on a gentle cycle with cool water. Hang them to dry rather than putting them in a dryer, as high heat can damage the Lycra™ fibers over time.
Do you have sizes for very tall or very short riders?
Yes! We offer Tall, Short, and Big versions of our gear. This ensures that the 5 × 12 inch elbow armor and the 5.25 × 12 inch knee armor sit exactly where they are supposed to, regardless of your height.
How long does the Bohn armor last?
Our SAS-TEC armor is high-quality and built to last up to 10 years. Unlike some cheaper foams that become brittle and dry out after a few summers, our pads stay flexible and effective for a long time.
Will this gear fit under my regular jeans?
Absolutely. Our armored mesh pants are designed to be "invisible" under standard-fit jeans. If you wear very "skinny" or tight fashion jeans, you might see the outline of the pads, but they fit perfectly under regular, relaxed, or carpenter-style pants.
Is Bohn gear made in the USA?
We are headquartered in Mooresville, NC, and our gear is designed in the USA. Some of our manufacturing also takes place right here in the states, and we handle all of our quality control and shipping from our North Carolina facility.
