Sizing and Alterations
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Please call us at 800.222.1994 or email us for ordering information.




We are experts at providing a great fit. We have lots of practice. Since 1983 we've talked to thousands of riders about their size, bike, climate and riding applications. Now we use a form that was developed to help our staff ask the right questions so you'll get your suit or Darien size perfect. Our most experienced associates do this successfully 98% of the time and our newer staff members are well coached. Every new order is double checked. Ordering factory direct gives you access to more sizes that are available at a shop or from a distributor catalog. The two-piece Roadcrafter comes in twenty-three different off-the-rack standard sizes. Let us help you find the one that provides the most perfect, precise fit. You will not be disappointed.


For larger groups of Officers, we can provide on-site sizing. An experienced associate will assist your personnel at your station.

Click for larger view. Also available in a PDF.

This chart lists equivalent clothing sizes. The numbers are approximate guidelines and do not represent actual body or Aerostich measurements. If you're not sure of your size, see our custom sizing tool online or call 800-222-1994 and we will help you get the right fit. If you wear a size 40 men's suit, the same size Aerostich Roadcrafter Suit or Darien Jacket will fit over your street clothes. Roadcrafter One and Two Piece Suits are available in 34 Regular and 36-54 Short, Regular or Long sizes. The Darien and Darien Light Jackets are available in 36-54 Regular sizes.



A V-shaped panel from the waist to the sleeve on each side of the suit meets another V-shaped panel from the elbow to the armhole, providing additional shoulder and arm ease. Ideal for athletic builds. Roadcrafter only. Add up to 2" at each side.
#203 $75.00


Shorten or lengthen up to a total of 2" above elbow, below elbow, or a combination of both. Price includes both sleeves.
#201 $75.00


Shorten or lengthen up to a total of 3" above knee, below knee, or a combination of both. Price includes both legs. (Length adjustment of rise is not available.)
#202 $75.00

*More alteration options are available. Please contact us for more details.

Reflective Lettering

POLICE, STATE TROOPER, SHERIFF, or RANGER. (Actual letter size is 3" tall.)


Available Colors

Standard Roadcrafter and Darien colors are available depending on your needs. Our Hi-Viz Lime Yellow ensures visibility for enhanced safety in traffic situations. Please call for a free sample swatch.




Compared to leather of the same weight and thickness, Cordura nylon is a stronger material. But hides are thicker and heavier so they offer greater abrasion resistance. We repair about twenty or thirty Aerostich garments a month. About a third of these were in crashes that produced some abrasion damage. Several common themes have emerged. Though Aerostich suits are not as abrasion resistant as racing leathers, they offer significant and useful protection, especially at typical street speeds.

Aerostich wearers often think of their suit as sacrificial in the same way a car's airbag gets used up by its deployment. These garments are lighter, cooler and easier to use in bad weather (etc...), but less crash-durable than leathers. On average, street riders seem to crash only at infrequent intervals. How gear feels and works during the intervening years of use and the tens of thousands of miles of riding is very important. Most street crashes occur between 20 and 50 mph, not between 50 and 100. For each Roadcrafter suit that was in a 100 mph crash, we get dozens that need smaller repairs because the rider fell down at 35 mph . For these kinds of everyday spills, even the fanciest leathers do not offer protective advantages. We make gear to help you use a motorcycle more and be better protected. It has to be safe, easy to use, and comfortable for everyday riding.


Although we have not conducted tests comparing the friction coefficients of cordura suits and leathers on various pavement surfaces, we have collected a significant amount of relevant information. We repair many Aerostich suits every year, and most of these are damaged by sliding on all kinds of pavements. Many of the wearers (testers....?) had previous crash experiences with leathers. Post-crash wearers typically comment that their Aerostich was 'slipperier' than their old leathers. The consensus is that Cordura slides a little better and tends to roll and tumble the wearer somewhat less than leather. After studying hundreds of accidents, former Motorcyclist magazine editor and professional accident reconstructionist Gordon Jennings believed that more crash injuries (broken shoulders, etc..) were caused by tumbling than by the incrementally increased chances of hitting something due to sliding farther.


Between 20 and 40 miles per hour, Roadcrafter suits usually sustain less than $250 of damage; between 40-70 miles per hour, $250-$500 of damage; 70-100 miles per hour, $500 or more. These figures are estimates - the actual amount of damage varies depending on the circumstances of each accident. A suit is 'totaled' and cannot be repaired if the cost of the repairs exceeds half of the price of a new suit. You will be contacted with an itemized estimate of repairs needed, based on time and materials, before work is begun. Garment should be cleaned and pads removed before returning. Cleaning service available. Garments are usually completed and shipped within two weeks.


Broken zippers, torn linings, melted ballistics and other repairs are estimated based on the materials and labor involved. Replacing a zipper or some hook and loop is usually between $30 and $60, but we will contact you with an estimate before performing any work. Garment should be cleaned (but not waterproofed) and pads removed before returning for repair. Cleaning service available. Garments are usually completed and shipped within two weeks.


The Roadcrafter provides more double layers of fabric over a larger area than the Darien. These include the elbow/shoulder/knee areas of ballistics nylon and additional Roadcrafter pockets. On the other hand, the Darien is lighter and cooler to wear. Crash events most commonly occur between 30 and 70 mph. Within this range the Darien, DarienLight and Roadcrafter all provide useful abrasion protection. All three provide more than jeans and windbreaker jackets. Riders on powerful sport bikes will prefer the closer fit and greater protection a Roadcrafter suit offers. Roadcrafters are available in short, regular, and long, and Dariens are all regulars, so if you are extra short or tall, go with the Roadcrafter. Getting a good fit is more important than the functional differences.


We are experts at providing a great fit. We've talked to thousands of riders about their size, bike, local climate and personal riding applications. We use a questionnaire to help learn the right things, so you'll get the best fit with your Roadcrafter or Darien. Our most experienced associates do this successfully about 90% of the time. Every order is double checked for accuracy. Ordering factory direct gives you access to more sizes than are available elsewhere. The one piece Roadcrafter comes in twenty-five different off-the-rack standard sizes. Let us help you find the one that provides the most perfect, precise fit.


Compared to men of the same height, women usually have slightly narrower shoulders, slightly longer legs and arms, and slightly shorter torsos. Roadcrafters and Dariens are looser fitting designs. About 60% of all women find Aerostich suits fit well without alterations. Of the remaining 40%, about half of these can enjoy a good fit after minor sleeve/arm/gusset/etc...alterations. Only about 20% of women (and 10% of men) cannot be fitted within the range of available sizes and custom alterations. Fully tailor made garments are not available.


After the manufacturing process that bonds a breathable/waterproof membrane to Cordura fabric, a DWR (Durable Water Repellent) chemical treatment is applied that prevents water from being absorbed into the Cordura’s fibers. If the Cordura fibers become saturated in wet conditions, the water forms a barrier causing vapor to condense on the inside surface. Over time and after extended wear, the original DWR treatment wears away and must be renewed. Periodically laundering gear with a wash-in treatment like Nikwax TX Direct®, or applying a post-wash water repellent product like Scotchgard®, Revivex® or Granger®, will insure that water beads and runs off the fabric, and that vapor will always be able to pass through, even in wet conditions. Maintaining the DWR also helps textile gear dry faster after being in rain.


Machine washing is recommended. Remove the TF2 pads and the contents of all the pockets. Close all zippers. Use the regular wash cycle, and a 'warm' water setting with mild powder detergent, wash-in water repellent products, or non-detergent soaps formulated specifically for outdoor fabrics. Run the complete wash/rinse cycle a second or third time with water only to remove any residual detergent. Machine dry at a medium temperature. Do not use anti-static products. Velcro® hook fasteners pick up lint so avoid laundering with cotton towels. Clean Velcro hook using a fine comb. Small stains can be removed using spot cleaning stain removal products. Citrus based cleaners work well for oil stains.



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