It's 85℉, the sun is beating down, and you're staring at your gear closet trying to decide between "sweating to death" or "freezing later." Choosing the right gear often feels like a gamble: pick the wrong fabric and you spend your entire ride miserable, either soaked in sweat or shivering when the sun goes down.
At Bohn Body Armor, we solved the armor-in-jacket problem over 25 years ago by separating the armor from the jacket with our base layers, but riders still ask me one question more than any other: "Should I get the Cool-Air Mesh or the All-Season Airtex?"
Beat the heat or the chill—Bohn’s Cool-Air Mesh and All-Season Airtex give riders perfect comfort with armor-ready versatility.
If you are stuck on this decision, this guide is for you.
The Quick Answer: Which One Are You?
If you want the cheat sheet before we dive deep, here is how most riders decide:
Bohn Cool-Air Mesh Armored Shirt: Buy this if you ride in humidity (Southeast, Midwest summers) or temps consistently over 85℉. It is like wearing a screen door—maximum airflow.
Bohn All-Season Airtex Armored Shirt: Buy this if you want one shirt for everything. It fits like a second skin, works perfectly from 60℉ to 90℉, and layers easily under cooler outer gear.
3 Truths About Riding Fabrics (That Most Brands Won't Tell You)
Before we compare the fabrics, let's clear up a few misconceptions about "summer gear."
1. "Mesh" isn't always cooler. Not all mesh is created equal. Some "mesh" jackets are made of heavy, plastic-coated nylon that barely breathes. Real cooling requires a fabric that wicks sweat and allows air to hit your skin directly to evaporate it.
2. The "All-Season" label is usually a lie. Most "All-Season" jackets are just winter jackets with a few vents. They're too hot for July and too drafty for January. True all-season comfort only comes from layering properly close to your skin.
3. If your armor is shifting or chafing, you're wearing the wrong size. Whether you choose Cool-Air or Airtex, the fabric should hug you tight enough that the armor stays securely in place. Properly fitted armor shouldn't move around or cause discomfort during your ride.
Contender 1: The Cool-Air Mesh (The Heat Killer)
What is it? The Cool-Air Mesh is our dedicated hot-weather fabric. It is constructed from a 100% open-weave mesh. Think of it as a heavy-duty net that holds the armor in place but has almost zero wind resistance.
Ultra-open mesh for max airflow and evaporative cooling—perfect for hot, humid rides. Ideal for heavy sweaters, Southern heat, and off-road.
The "Superpower": Evaporative Cooling In high humidity (like we have here in North Carolina or down in Florida), sweat doesn't evaporate easily. It just sits on your skin, making you feel sticky and hot. The Cool-Air Mesh allows 100% airflow to reach your skin. When you are moving, that air hits the sweat and forces evaporation, which actively lowers your body temperature.
Who is it for?
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The "Sweater": If you start sweating the moment you look at your bike.
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The Deep South Rider: If you ride in 90% humidity.
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The Off-Roader: If you are working hard on the trails and generating a lot of body heat.
Trade-off: Because it is so airy, it can be chilly if the temperature drops below 70℉. If you ride in cooler mornings, you may want a wind-blocking layer over it.
Contender 2: The All-Season Airtex (The Daily Driver)
What is it? The Airtex (often called our "All-Season" line) is a hybrid fabric. It combines soft, stretchy Lycra™ with ventilated mesh panels.
Soft Lycra™ + mesh hybrid for all-day comfort and balanced airflow—ideal for commuters, tourers, and riders who prefer a smooth, athletic feel.
The “Superpower”: Comfort You Can Layer or Ride In
The Airtex is a smooth, athletic fabric designed for riders who want one layer that does it all. It’s soft and comfortable enough to wear directly on the skin, holds armor securely in place, and looks clean and sporty when worn on its own. It breathes well for warm, dry days, while offering just enough wind resistance to stay comfortable as temperatures change—making it ideal for riders who plan to peel down to a single layer at some point in the ride.
Who it’s for
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The Commuter: Cool mornings, warm afternoons.
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The Tourer: One piece that adapts across changing conditions.
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The Style-Conscious Rider: Wants armor they can wear as an outer layer without looking like base gear.
Trade-off
In extreme heat or heavy humidity, it won’t move as much air as Cool-Air, and can feel warmer when stopped.
The "Touch Test": How Do They Feel?
I often describe the difference like this:
Cool-Air Mesh: The Cool-Air material uses a lightweight, open-weave mesh designed for maximum airflow. It feels stretchy and breathable, and its main job is to keep the armor securely in place while allowing as much ventilation as possible—great for hot weather riding.
Airtex: The Airtex material is made from a combination of soft Lycra and mid-weight mesh, giving it a smoother, softer feel against the skin. It layers easily under riding pants or a leather jacket without bunching and offers a balance of comfort, ventilation, and durability.
Cool-Air Mesh features ultra-open weave construction for maximum airflow in hot conditions.
Both fabrics use the exact same CE-Level 2 armor. You're not sacrificing safety by choosing one over the other. The armor coverage protects your shoulders, elbows, back, hips, knees, and shins—the key impact zones in most crashes.
The Verdict: Can You Mix and Match?
Absolutely. In fact, many riders do exactly that.
A very common setup is mixing Bohn shirts: using the Cool-Air Shirt when maximum airflow and cooling are needed, then switching to the Airtex Shirt when you want a smoother, more versatile layer you can also wear on its own. Because both shirts use the same armor system, the pads transfer easily between them—so you can choose the fabric that fits the ride without buying duplicate armor.
Popular combination—Cool-Air shirt with Original pants for optimal comfort across different body zones.
Remember, the beauty of the Bohn system is that the armor is removable and interchangeable. You can buy one set of armor and both shells (Cool-Air for July, Airtex for October) and swap them out. It's the most cost-effective way to have a true 4-season riding wardrobe.
Frequently Asked Questions
Is the sizing the same for both?
Yes. Whether you choose Cool-Air or Airtex, our sizing runs from 3XS to 5XL with Tall, Short, and Big options (fitting riders from 4'9" to 6'10"). Both fabrics are stretchy, so they're forgiving if you're between sizes.
Is the Airtex "hot"?
The Airtex is not hot. It is made from breathable mid-weight mesh fabric with stretchy Lycra panels that are breathable and cool. It is much cooler than a traditional textile jacket, though not as open as the Cool-Air.
Do I wear anything under them?
For the shirts, you can wear them with or without a t-shirt underneath depending on your personal preference.
Which one is better for abrasion?
Neither Cool-Air nor Airtex is designed for abrasion resistance. The main design function is impact protection with our CE-Level 2 armor from SAS-TEC. While the armor pieces offer some abrasion resistance, the fabric itself is not reinforced with DuPont Kevlar® or Cordura. You should always wear an abrasion-resistant outer layer.
I live in California/Arizona (Dry Heat). Which one?
For dry heat conditions, the Airtex works well for most temperatures. However, the Cool-Air is specifically popular for people who ride in very hot and for extreme temperatures over 100℉, the Cool-Air's lightweight elastic mesh provides maximum airflow.
