Hot-Weather Flying: 7 Gear Tips Every Pilot & Flight Crew Needs This Summer

by an aviation-gear professional for EMS crews, aerial firefighters, utility operators and ag pilots gearing up for heat-wave missions.

The 120 °F Reality Check

“When ramp temps top 120 °F / 49 °C, many medical helicopters can’t launch at all.” — National Park Service release after a 128 °F Death Valley rescue (The Washington Post)

Research shows cockpit heat indices climb ˜ 13 °F (7 °C) above ambient in just one hour of standby (PubMed). Beating heat isn’t a comfort perk, it’s operational insurance.

Below are seven proven gear ideas and summer heat beating tips that keep rotor-wing crews & ag & fixed wing pilots alert, hydrated and mission-capable when asphalt shimmers and gearbox temps climb.


1. Comfort “Moisture-Wicking” Helmet Liners

Comfort Liner for EVO Helmets

Key insight – Upgrade fit and sweat control for sharper focus in the heat.

Why it matters
Standard pads absorb sweat and stay damp. The memory-foam Comfort Liner for EVO HPH Helmets uses quick-dry fabric that helps reduce hot spots and keeps comms pads cleaner during long summer shifts.

Field example
A utility pilot on Phoenix bucket ops reported less skin irritation and clearer audio after upgrading to this liner on double-shift days.

Try it: Comfort Liner for EVO HPH Helmets — available in five thicknesses to fine-tune fit; memory-foam construction retains shape flight after flight.

Pros — cushioned fit, dries faster than stock pads, compatible with internal comms
Cons — not vented for airflow; pair with a skull cap for heavy-sweat missions


2. Summer-Weight Nomex® Flight Suits

Key insight – 4.5 oz Nomex sheds heat yet meets U.S. military spec FNS/PD 96-17.

BenefitTrade-Off
Flame-resistant DuPont™ Nomex® fabricSlightly less abrasion resistance vs. 6 oz
Two-way zipper & six pockets for gearNeeds base layer in winter
Gusseted back + adjustable Velcro® waistPrice premium over poly blends

Gear up:Propper CWU-27/P 4.5 oz Nomex Flight Suit — original military-issue design with knife pocket, NIR-compliant tan & sage options, and sizes 34–52 Short/Reg/Long.

Image placeholder: pilot loading patient while wearing tan CWU-27/P.


3. Grey & Gradient Style Visors

Key insight – Tinted inner lenses cut glare up to 60 % while staying NVG-friendly.

  • **Grey** lens = daytime glare shield for water-bucket runs.
  • **Amber** lens boosts contrast in dusty, brown-out LZs (think smoke and fire conditions found in summers out in western USA).
  • Dual-visor EVO setups flip from day tint to NVG-clear in seconds.

Upgrade:Inner Visor (Tinted) for EVO & LXL MSA — available in Grey, Amber, and Clear; fits EVO 052/152/252 and LXL MSA Gallet models.

Pro — easy to change also  can be a tool-less swap in the field if using a Quick Release EVO 252R
Con — darker tints dull at dusk; stow a clear spare or make sure one of the visors installed is clear.


Hydration-ready medical pack

4. Hands-Free Hydration Packs

Key insight – 4–6 oz every 20 min prevents a 2 % fluid loss that degrades reaction time.

  • Low-profile 1.5 L bladders stow under or behind seats; bite-valve routes through harness.
  • Insulated stainless bottles survive cockpit drops and rotor wash.
  • Electrolyte stick packs avoid sugar crashes on 100-minute fire turns.

FAA medical guidance warns that even 1 % dehydration slows cognitive processing in hot-day ops (PubMed).

Suggested solution:Medic Trauma Pack (CCRK) — MOLLE-ready pack with hydration-sleeve compatibility and quick-release shoulder straps.


5. Moisture-Wicking Skull Caps

Key insight – Italian-made cotton caps keep sweat off pads and extend liner life.

  • United Designs cotton developed for pilots in the Middle East.
  • One-size stretch slips under any SPH or EVO shell without shifting lenses.
  • Machine-washable; rotate two caps for every crew member.

Stock up : Cotton Skull Cap – One Size Fits All

Pros — protects helmet interior, budget-friendly
Cons — cotton dries slower than synthetics; swap during turnarounds.


6. Nomex Flight Gloves, Hot-Weather Cut

Key insight – Thin FR leather palms preserve tactile feel while resisting 700 °F flash.

  • Premium leather palm & fingers with double-stitched trigger-finger pattern.
  • Form-fitting Nomex® back; heat & fire resistant to 700 °F.
  • Elastic gather on glove back keeps fit snug in turbulence.

Equip: Government-Issue Nomex Flight Gloves


7. Smart Heat-Monitoring & “Summer Armor” Pouch

Key insight – Live cabin-temp alerts prompt hydration and altitude changes before impairment.

  • Stick-on Bluetooth sensors ping at 95 °F cockpit-temp threshold.
  • Clip-on hygrometers flag humidity spikes that jack sweat rate.
  • ACR Bivy Stick pushes satellite weather and SOS from any LZ.
  • Pack spare skull cap, electrolyte tabs, microfiber towel and lightweight gloves.

Bottom Line

Heat stress cripples performance long before the torque gauge redlines. Memory-foam helicopter flight helmet liners, 4.5 oz Nomex suits, grey & amber visors, hydration-ready packs, Italian cotton skull caps, FR flight gloves and live cockpit-temp sensors build a layered defense that keeps EMS teams sharp, utility crews productive and aerial firefighters safe when the mercury spikes.

Save our free Summer Flight-Gear Checklist and compare it to your current setup. What trick or piece of kit has saved your crew on triple-digit days? Share your tip below or tag @aviationsurvivalglobal (instagramon social.