About: Just a guy who doesn't know when to quit, and is constantly in search of a solution to a problem that doesn't exist yet.
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Difficulty:Easy
Tool Requirements:Low
Time:1h 30min
Cost:25-30$
Synopsis:
Problem: I wanted cheap, comfortable replacement hip armor inserts, and I was unsatisfied with the commercially available solutions.
Solution: I butchered a CE Rated Back Protector pad and made my own. The result was fantastic so on my second or third time doing the project, I decided to document it.
Intro:
So sometime ago, I upgraded some kevlar jeans to give them maximum protection in a casual looking package. Don't worry, there's an interesting instructable for that, too. Among the upgrades was a tailbone protector. And given that no one sold standalone, CE rated tailbone protectors, I decided the cheapest and easiest way to get one would be to cut up a cheap Icon D3O CE Level 1 Back Protector and use that. With the material I had left over, I made some hip armor for some other riding jeans I had. The result was so good that these days I'd rather do that than buy the commercial solutions.
And it's not that I haven't tried them. As far as hip armor goes I've tried the Icon D3O Evo X Hip Armor, the Forcefield 4-Layer Replacement Hip Armor and Alpinestars Nucleon Hip Armor, among others. This is still the armor I've found most pleasant for the smallest amound of money. It only rivals Forcefield NET Upgrade Armor, but that costs more. By the way, this project may be updated over time. Click here to see the latest version.
So here we go, let's begin!
Disclaimers:
Motorcycling is a dangerous activity, and no amount of protection will ever guarantee walking away from an accident without injury. Anyone who decides to follow this tutorial must do it at their own risk and under their own exclusive responsibility. Neither this Instructable nor it's author make any claims about the performance of this armor, and any allusions to CE ratings refer to the undamaged, unmodified original piece of equipment as the manufacturer intended.
A bit of motivation to keep making instructables always helps. I'm a participant in the Amazon Services LLC Associates Program as well as eBay Partner Network, affiliate advertising programs designed to provide a means for creators to earn fees by linking to their sites, at no extra cost whatsoever to you.
Armor is sold in pairs so you only need to order one set per pair of pants!!
Unlike many other types of commonly available motorcycle protection, our armor is multi-impact compliant. That means it remains fully functional even after repeated hits. There is no need to replace your armor after an unscheduled dismount unless it is significantly damaged.
Level 2 Armor is European designed and manufactured (by SAS-TEC Germany), to provide maximum comfort as well as maximum protection. The viscoelastic soft foam (commonly referred to as Tripleflex armor) is lightweight and conforms to your anatomy for all-day wearability yet reacts immediately to disperse the force of even minor impacts away from the human body. Its system of interlocking polygons allows it to flex and move with the rider but lock into position to provide full-coverage protection.
Maybe you are looking to replace the useless foam that comes with many suits and pants? Upgrade your suit to Bohn Armor! Many suit manufacturers simply use comfort foam to pad out shoulders, etc., which provides little to no actual protection. After all, their business is to sell you a nice suit, not armor!
This pair of hip armor pieces allows you to replace the outdated hip armor in your pants or shorts without having to purchase a new shell, making it easy to continue riding in your favorite Bohn gear!
Q: What is Level 2 armor?
A: Here&#;s the official answer: CE Level 2 limb armor conforms to CE Level 2 standard if the average transmitted force of nine tests is less than 20 kN for limb armor and 9kN for back armor.
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Translated into everyday English, CE Level 2 armor dissipates force better than CE Level 1 .
Q: Do I need Level 2 Armor?
A: Truly it is a preference as to what level of protection you are looking for. For most street and dual sport riders riding safely and within the speed limit, CE Level 1 protection is sufficient. Companies still produce Level 1 armor and some are made with even the newest technologies. At Bohn Armor, we&#;ll be riding with the new Level 2 product as it is designed specifically for our garments to make them extremely comfortable, lighter, more ventilated and come with the latest technology. We feel that our newest iteration is our best yet!
Q: Why are your thigh and tailbone armor pieces not CE-rated?
A: While our thigh armor and tailbone armor are made with Level 1 certified materials used for the hip, knee, shin, shoulder and elbow, what most people don&#;t realize is that those particular armor pieces cannot be officially certified Level 1 OR 2. There is just no certification/test for that. We offer those pieces for extra added protection where most other companies don&#;t.
We want our riders to be safe and the thighs and tailbone are also quite vulnerable to injury and road rash. However, what is really fantastic about the thigh and tailbone pieces is that they are made from incredible materials so they are super thin, and lightweight and still provide the best protection available for those areas. No other company can say that about their pants!
Q: Is this D3O®? Does it harden on impact?
A: D3O® is a non-Newtonian polymer which means that it is soft and malleable in a non-stressed state but it instantly hardens when sudden stress (impact) is applied.
The Bohn Level 2 Armor, on the other hand, features progressive absorption as demonstrated in Newton&#;s Third Law of Motion (for every action [force] in nature there is an equal and opposite reaction). That means the air that is embedded within the cells of the foam resists force in direct response to how much force it is being subjected to. This characteristic allows the armor to effectively dissipate force at both high and low-impact speeds.
Q: What is the average lifespan on the Level 2 Armor?
A: Depending on the amount of riding you do, as well as your individual riding conditions, the viscoelastic foam could potentially last up to ten years.
Also, keep in mind that armor technology improves greatly every few years so you should find that each new set you purchase is much further ahead in quality, fit, feel and technology from what you had before.
Q: How do I take care of the armor pieces? What&#;s the best way to store them when I&#;m not riding?
A: We recommend removing the armor from your Bohn gear from time to time to clean it as detergent residue, salt (including body salt) and moisture can stick to it and negatively affect the armor.
Armor pieces should NOT be placed in the washing machine or dryer, but may be wiped clean with a damp cloth if they become soiled.
During the off-season, we recommend storing in a cool, dry place away from direct sunlight. It is always a good idea to give everything a thorough cleaning before storing it away and we also recommend not storing it in a rolled or folded position as that can cause undue stress on the armor, causing it to wear out quicker.
Q: Does it need to be replaced after a crash?
A: Bohn Level 2 Armor has long-lasting crash construction and is meant for repeat use. If you go down, merely inspect for visible damage. If the damage is significant then you will need to replace the armor piece(s), if it is simply scratched, you do not have to replace it, simply sand off any hard or sharp edges and continue to use.
Q: Will these fit in the Bohn gear that I already own?
A: The new Bohn Level 2 Armor pieces have been designed to fit within the existing pockets of your Bohn Armored Pants, Shirts and Shorts. They are universally sized so they are also compatible with most other brands of protective gear.
Q: What side of the flexible flat armor goes against my body?
A: While your first instinct may be to insert the armor with the interlocking part away from you, it is actually designed to have the solid part as the outer surface. The channels between the polygon &#;nubs&#; allow for more airflow to the skin, which leads to a more comfortable ride overall.
Q. Can I use these protectors in the cold?
A. Yes you can. But you need to warm them to your body before you use them in the cold. See the tab for care for more information on this.
Q: I am sensitive to latex. Is your armor safe for me to wear?
A: The comfort of our customers ranks second only to their safety. The Bohn Level 2 Armor is latex free.
Contact us to discuss your requirements of custom motorcycle tailbone pads. Our experienced sales team can help you identify the options that best suit your needs.