So you don’t want to look like a Power Ranger on the road? I don’t blame you – but your casual shirts (even a sturdy flannel) are not doing you any favors if you hit the pavement. 

At Bohn Body Armor, we have spent over 25 years helping riders find gear that feels like regular clothes but still works when it counts. We know that most riders just want to be comfortable and look good while they are out on a Saturday cruise.

But there’s a catch to the traditional “armored flannel” for motorcycling. 

If you buy a flannel that is too big or has loose armor pockets, the pads will shift away from your joints the moment you hit the ground. This leaves your skin and bones exposed to the hard road, which can lead to painful injuries that take a long time to heal.

Choosing the right armored flannel is about more than just picking a cool color or pattern. Let's look at how to pick a flannel that actually does its job.

Bohn flannels give the classic look and comfort of regular shirts with discreet armor that stays in place for real protection.

Two Approaches to Armored Flannels

The motorcycle gear industry has developed two distinct approaches to providing the "flannel style" with serious protection.

Approach 1: Integrated Armored Flannels

Brands like Pando Moto, Saint Unbreakable, Tobacco Motorwear, and Rokker build the protection directly into the flannel. You put on one shirt and you're done.

Pros: One-piece simplicity with reinforcement built in. Looks exactly like a regular flannel and quick to wear. Sometimes sold with armor in elbows, shoulders, and back.

Cons: Armor pads are often small without the highest protection available. A loose fit also allows armor to shift. Your style on the bike is also limited to that one flannel.

Approach 2: Base Layer System with Protective Outer Flannel

This approach uses a tight-fitting armored base layer paired with a fully-lined protective flannel on top.

Pros: Armor stays locked in place with the snug base layer. Full coverage for abrasion can still be added with a fully Kevlar-lined flannel, or another other abrasion-resistant layer on top. 

The fundamental difference is comprehensive protection versus convenience. The modular system allows you to combine a base layer that keeps armor positioned correctly while layering over a fully Kevlar-lined outer flannel that protects every inch of your skin.

Why Partial Protection Fails

When you look at a typical armored flannel, you'll find Kevlar patches at the elbows and shoulders. This is better than nothing, but it leaves your sides, back, and forearms vulnerable. If you slide on your back where there is no lining, the cotton will tear through in a very short time. 

The armor pocket issue is even more critical. A flannel that fits loose enough to look normal will allow those CE armor pads to move during a crash. I've seen crash reports from riders wearing traditional motorcycle flannels who ended up with elbow injuries because the sleeve twisted during the fall.

Cheap flannels protect only in patches. Bohn flannels have full high-strength lining for invisible, all-over protection against road abrasion.

At Bohn Body Armor, we take a very different approach. We build the armored underlayer to lock your impact protection in place, then offer flannels built with a full lining of high-strength Kevlar, meaning every inch of the shirt is designed to handle abrasion. By lining the whole shirt and pairing it with a snug base layer that holds SAS-TEC armor in place, we give you comprehensive protection.

Top Recommendations for New Bohn Riders

Now that you understand why the base layer plus fully-lined flannel approach works better, let's look at which Bohn products deliver this protection. These three items create a complete system.

Bohn Protective Flannel Layer

This is our dedicated riding flannel built with full abrasion-resistant Kevlar lining. Many brands only put protective patches on elbows and shoulders, but we line the entire shirt for better coverage. It features heavy-duty snaps and a hidden zipper to keep the shirt closed during a fall.

Get the Bohn Flannel Riding Shirt

All-Season Airtex Armored Shirt

This is the base layer to pair underneath a protective outer layer like our riding flannel. Made of soft, stretchy Lycra™, it holds CE-Level 2 certified SAS-TEC armor tight against your shoulders, elbows, and back. You wear this under any regular flannel you already own, and it keeps the protection locked onto your body.

Get the Airtex Armored Shirt

All-Season Armored Pants

To complete your casual look, these armored pants fit under your favorite riding jeans. They feature 5.25 × 12 inch knee and shin SAS-TEC armor that stays in place while you move. The fabric is very flexible and thin yet still CE-Level 2 approved, so you don't look like you are wearing bulky gear.

Get the All-Season Armored Pants

The Best Armored Flannels: Outer Layers

Not happy with our flannel options at Bohn? Here are several established brands that have earned solid reputations in the motorcycle community that still pair well with Bohn’s base layers. 

Tobacco Motorwear

Tobacco Motorwear brings a vintage aesthetic to the armored flannel market. Their shirts use Dyneema-reinforced construction for extremely high abrasion resistance. The designs are inspired by classic workwear and heritage motorcycle culture.

These flannels are no doubt durable and offer a timeless style. They look like traditional flannel shirts but perform like modern riding gear.

Riders choose Tobacco Motorwear for both style and safety. The Dyneema panels ensure reliable impact and abrasion protection.

John Doe

John Doe applies German engineering to create flannels with XTM fiber integration. This fabric combines aramid, Coolmax, and elastane for strength, cooling, and flexibility. The result is a soft yet abrasion-resistant flannel.

Their flannels are designed for all-day wear on and off the bike. Comfort is prioritized alongside protection. The shirts are positioned as premium everyday riding wear.

Riders enjoy Speed and Strength for its practical protection and good value. These aren’t the most premium flannels on the market, but they’ll get the job done around town. 

The Challenge with Popular Flannels

Most armored flannels use partial reinforcement, adding protection only at elbows, shoulders, and sometimes the back. This leaves large areas of regular cotton exposed.

If the flannel fits loose enough to look normal, the armor can shift during a crash. These limitations are common across nearly every flannel-style riding shirt.

Bohn’s Armored Flannel is fully Kevlar-lined at an affordable price for a high-value option to layer over your impact protection base layer.  

3 Truths About Motorcycle Gear

Truth 1: The Thud Matters More Than the Drag

Most people worry about "road rash" from sliding, but the first hard hit often causes the most trouble. When you fall, your body hits the ground with a lot of force. You need gear that uses high-quality materials like SAS-TEC armor to soak up that energy.

This is where even premium flannels from Pando Moto and Rokker face challenges. Their Kevlar protects against abrasion, but if armor shifts during that initial impact, it doesn't help your elbow or shoulder.

Truth 2: Baggy Gear Is Risky Gear

If your flannel fits like a loose jacket, the armor inside has too much room to move around. If you fall and the sleeve twists, your elbow pad will end up on the side of your arm. Protection only works if it stays snug against your skin.

This affects every integrated armored flannel on the market because they all need to maintain that casual, comfortable fit. It's not a flaw from Saint Unbreakable or Tobacco Motorwear. It's a design constraint they can't escape.

Truth 3: Heat Makes You a Worse Rider

If your gear is too thick and makes you sweat, your brain slows down and you lose focus. Staying cool and comfortable helps you stay alert so you can make better decisions on the road. Lightweight, breathable gear isn't just about feeling good.

This is one area where modern armored flannels have made progress. Materials from Bull-It and John Doe are more comfortable than older protective gear. The base layer approach takes this further by letting you adjust your outer layer while keeping armor consistent.

Understanding SAS-TEC Armor Technology

We use SAS-TEC armor in all of our gear because it is a "smart" material. When you are just sitting on your bike or walking around, the armor is soft and flexible. It follows the shape of your body and doesn't feel like a stiff board.

However, if you hit the ground, the material hardens instantly to absorb the shock before it reaches your body. Once the pressure is gone, it becomes soft again. This material is also very durable and has an armor lifespan of up to 10 years.

SAS-TEC armor stays soft while riding, hardens on impact, then resets - lasting up to 10 years for long-term protection.

You'll find CE armor in Pando Moto and similar flannels, though they typically use harder foam inserts. The key advantage of SAS-TEC is the combination of impact absorption, flexibility, and long-term durability.

Why Fit Is Everything

If you are a rider who is super short or very tall, you know how hard it is to find gear that fits. A Pando Moto flannel sized for your chest might have sleeves that are too long. A Rokker that fits your torso might be too short if you're tall.

At Bohn, we offer a huge size range from 3XS to 5XL for riders from 4'9" or 6'10". We also have specific sizes for Tall, Short, and Big riders. Our gear is designed in the USA to fit real people of all shapes and sizes.

Gear that actually fits - sizes 3XS to 5XL, including Tall and Short - so armor stays in place and protects you properly.

When your gear fits your body correctly, the armor stays over your joints. You feel much more confident while you ride.

Protecting Your Lower Body

If you're wearing a flannel, chances are you're wearing jeans too. The problem is that regular denim offers almost no protection at 40 miles per hour. While riders often think about protecting their upper body, it's easy to forget that your legs are just as vulnerable in a crash.

Our armored pants are the perfect partner for a flannel shirt. They are thin enough to fit under any pair of jeans, even "slim fit" styles. They feature 5.25 × 12 inch knee and shin SAS-TEC armor and pads for your hips and tailbone.

Armored pants built to wear under your jeans - thin, flexible, with SAS-TEC knee, hip, and tailbone protection that stays hidden.

Because they are worn under your pants, they offer invisible protection that doesn't ruin your casual look.

The Bohn Philosophy: Comfort First

I have been riding for a long time, and I know that if gear is uncomfortable, you will eventually find an excuse not to wear it. You might say, "I'm just going down the street," and leave your heavy jacket at home. That is usually when things go wrong.

By making our gear lightweight and flexible, we take away the excuse to ride unprotected. Our Lycra™ fabrics are soft against the skin and don't have itchy seams. Whether you are commuting to work or taking a long trip, you will forget you are even wearing armor.

Size and Specifications for Peace of Mind

We want you to know exactly what you are getting. Our armor pieces are sized to cover the areas that get hit the most:

• Elbow/Forearm armor: 5 × 12 inches

• Knee/Shin armor: 5.25 × 12 inches

• Shoulder armor: 5 × 8 inches (Standard), 6 × 9 inches (3XL+)

All of our armor is CE-Level 1 or CE-Level 2. We choose these specific sizes because they provide the best balance of coverage and comfort.

FAQs

What is the best way to wear an armored flannel?

We recommend using a two-part system. Wear a Bohn Armored Shirt with SAS-TEC armor as your base layer to keep the protection snug against your body. Then, wear a high-quality flannel with a full protective lining over the top for style and abrasion resistance.

Will the armor move if I fall?

If you wear our armored base layer, the armor will stay in place. Unlike flannels with loose internal pockets, our Lycra™ shirts hold the 5 × 12 inch elbow and forearm armor tight against your joints so it cannot shift or rotate during a fall.

Is an armored flannel as safe as a leather jacket?

A high-quality leather jacket usually offers the best abrasion resistance. However, a flannel with a full protective lining and CE-certified SAS-TEC armor provides a very good balance of safety and comfort for most street riding. It is much better than a regular cotton shirt.

Can I use my own flannel with Bohn armor?

Yes! That is one of the best parts of our system. You can wear our All-Season Airtex Armored Shirt under any flannel you already own. This gives you invisible protection and allows you to keep your personal style while staying safe.

How do I know what size to get?

We offer sizes from 3XS to 5XL, including Tall, Short, and Big options. We fit riders from 4'9" to 6'10". You should choose a size that fits snugly but still allows you to move comfortably.

Is the armor heavy?

No, SAS-TEC armor is very lightweight. Most riders tell us they forget they are wearing it after just a few minutes on the bike. Because it is flexible and moves with your body, it doesn't feel like a heavy burden.

How do I wash my armored flannel system?

For the armored shirt, simply remove the SAS-TEC pads and wash the fabric shell in cold water. For your outer flannel, follow the care instructions on the tag. Removing the armor before washing helps the fabric last much longer.

Where is Bohn Body Armor located?

We are located in Mooresville, NC, just north of Charlotte. Our gear is designed in the USA, and we have been helping protect riders for over 25 years.