Upgrading the armor in your favorite riding jacket usually starts with a search for better inserts to replace those flimsy foam pads. At Bohn Body Armor, we’ve spent over 25 years helping riders find the right balance between real protection and all-day comfort, and armor is a huge piece of that.
Getting your armor setup wrong often means pads that shift around or feel like bricks against your joints. When you finally get the right fit, you stop worrying about your gear and start focusing on the road ahead.
You want gear that works when you need it but feels like it isn’t even there while you’re cruising, and that’s why we built our signature underlayers that I’ll get into later.
But we also sell the slim, CE-Level 2 SAS-TEC armor pads we use in our underlayers as standalone pieces you can insert into any other motorcycle jacket (or pants).
Choosing the right way to upgrade your impact protection changes everything about how you feel on your bike.
Upgrade flimsy pads to armor that fits right and looks invisible – so you forget the gear and enjoy the ride.
Bohn's Armor Inserts: High-Quality Protection for Your Existing Jackets
Here at Bohn, we stock a variety of SAS-TEC armor products for every part of the body from the back to the chest to the elbows, hips, knees, shoulders and more. We carry these pads in a variety of sizes as well.
Here are all the links for replacement armor by body part:
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Armor for Bohn Products (full sets to go in our shirts, pants and jackets)
Bohn's Armor Inserts bring high-quality CE-Level 2 SAS-TEC protection to your existing jackets. These standalone inserts are the same impact-resistant foam used in our shirts, trusted by riders every day. Flexible, breathable, and softening with body heat, they absorb massive impacts while moving naturally with your body.
Unlike bulky hard-shell armor, SAS-TEC delivers professional-grade protection without weight or stiffness. It significantly reduces force during a crash compared to Level 1 alternatives, giving riders top-tier safety in a comfortable design. Perfect for dropping into jacket pockets, these inserts upgrade your gear instantly.
Bohn SAS-TEC armor: CE-Level 2 protection that’s flexible, breathable, and absorbs impacts without bulk or stiffness.
Even premium armor can shift in loose pockets, which is why Bohn also offers armored shirts. The built-in SAS-TEC holds protection precisely over your bones while letting you wear any outer layer you like.
The Problem With Jacket Inserts
Many riders look for exactly these aforementioned CE-Level 2 armor inserts to upgrade their gear. While upgrading to high-quality SAS-TEC foam can help keep you safer, traditional motorcycle gear armor pockets are often oversized or poorly positioned for your body.
This can cause elbow armor to drift to the inside of your arm or shoulder pads to rotate toward your back, reducing protection.
Bohn solves this with jackets and armored shirts designed specifically for impact protection. Their body-close fit holds SAS-TEC armor exactly where it belongs – directly over your bones. Breathable mesh and Lycra™ blends stretch to your shape, keeping armor locked in place without shifting.
Loose jacket pockets let CE-Level 2 armor shift away from impact zones. Bohn’s body-close fit keeps protection exactly where it belongs.
With options like the Cool-Air mesh armored shirt or a fully armored Bohn jacket, you get reliable, “invisible” protection that fits comfortably and works with your riding style. One piece of gear gives you consistent protection without compromising fit or forcing you to retrofit every jacket in your closet.
Our armor also covers more area than most on the market: The elbow and forearm protector measures a massive 5 × 12 inches, shielding the entire forearm rather than just the elbow point. Shoulder armor comes in two sizes: a standard 5 × 8 inches and a larger 6 × 9 inches for 3XL to 5XL riders, ensuring proper coverage for riders of all heights, from 4’9” to 6’10”.
An armored shirt frees you from motorcycle-specific clothing. You can wear a hoodie, flannel, or vintage denim jacket and still have CE-Level 2 impact protection underneath.
The Value of Long-Term Protection
Buying inserts for multiple jackets often costs more than a single armored shirt. Since Bohn armor is removable from our shirts and pants, you can wash the garment easily or move the pads into one of our thermal shirts when temperatures drop or the Cool-Air Mesh when it’s blazing hot.
This is a “buy once, wear for years” investment. Jackets and bikes change, but your armor continues to work under whatever you wear next.
Frequently Asked Questions
Is CE-Level 2 better than Level 1?
Yes. CE-Level 2 armor transmits less force during impact. All Bohn shirts include CE-Level 2 protection.
Can I wear a Bohn shirt by itself?
It’s possible – many riders do – but not recommended. Bohn shirts are designed as base layers and should be paired with an abrasion-resistant outer layer.
How do I choose the right size?
Follow the size chart and measure yourself while wearing a thin base layer.
Will the armor feel heavy?
SAS-TEC is flexible and lightweight. It softens with body heat, and most riders forget it’s there after a few minutes.
What happens if I crash?
Fabric may show wear, but armor pockets should remain secure. The armor itself is reusable unless physically damaged.
Does Bohn offer chest protection?
Our standard Airtex shirts focus on back, shoulders, and elbows. The Airtex Adventure shirt includes chest protection.
