Clothing is part of your safety system. The right layers keep you cooler on the ramp, focused in the seat, and protected when the mission turns rough. Here’s how pros kit up from head to toe, with pieces that actually earn their space.
What to Wear: Flight Suits, Gloves, Liners and Smart Add-ons
Start with flame-resistant coverage that fits right. Add moisture control at contact points. Finish with visibility and glare control so your eyes and hands stay sharp. Below you’ll find battle-tested picks, quick comparisons, and sizing tips you can use today.
Quick compare
| Item | Why it matters | Best for | Watch-outs |
|---|---|---|---|
| Nomex flight suit, 4.5 oz | FR coverage with better heat shedding and mobility | Hot ramps, long summer sorties | Slightly less abrasion resistance than 6 oz |
| Nomex flight gloves | Tactile feel on switches; FR protection | All seasons; night and NVG work | Size to a snug finger fit |
| Moisture-wicking skull cap | Keeps sweat off pads; improves hygiene | High-heat missions; shared helmets | Swap mid-shift if soaked |
| Comfort liner (helmet) | Reduces hot spots; steadies comms fit | All-day wear; turbulence | Choose thickness to match shell |
| Tinted inner visor | Cuts glare; preserves contrast in brownout and haze | Day ops; water glare; fire smoke | Keep a clear lens ready for dusk |
Flight clothing that earns its place
US military pattern with FR Nomex, two-way zipper, gusseted back and multiple tool pockets.
Fit tip Measure chest and inseam, then pick Short, Regular or Long. If between sizes, prioritize torso length for comfort in the seat.
Thin leather palm with FR back for switch feel, radios and map work.
Fit tip Fingers should be snug with no extra fold at the tips. If you’re between sizes, size down for precision.
Simple sweat barrier that protects helmet pads and reduces salt build-up.
Use tip Rotate two per shift. Swap when saturated to keep comms pads dry.
Memory-foam liner that evens out pressure and keeps the shell stable through turbulence.
Fit tip Available in multiple thicknesses. Choose the thinnest that still removes hot spots.
Grey for glare, amber for contrast in dust and smoke, clear for night. Swap fast to match conditions.
Use tip Keep a clear lens in your bag for dusk or overcast turns.
Heat day standby
Crew chief swaps a soaked skull cap at the one-hour mark. Pads stay dry, audio clears up, and the next turn is easier.
Brownout approach
Pilot flips to amber visor before entering the dust. Better contrast on wires and treeline in the cone.
How to size a CWU-27/P in 60 seconds
- Measure chest at full breath out and natural waist. Note inseam from crotch to floor in socks.
- Choose Short, Regular or Long by height and torso feel. If you’re long-torsoed, size for torso first.
- Try a light base layer under the suit and sit. You should reach forward without shoulder bind or groin pull.
Loadouts you can copy
- Summer ops CWU-27/P 4.5 oz + skull cap + tinted visor + Nomex gloves
- Training days CWU-27/P + comfort liner for long headset wear + spare skull cap
- Dust and glare CWU-27/P + amber visor + gloves with snug finger fit
FAQ
Flight suits
4.5 oz or 6 oz Nomex
4.5 oz runs cooler with easier mobility and meets FR needs for most missions. 6 oz adds abrasion resistance if you are hard on gear.
How should a suit fit
Comfortable reach with arms forward, no tight pull at shoulders or crotch when seated. Use torso length to decide between Short, Regular or Long.
Gloves
Can thin gloves still protect
Yes. The FR back protects while the leather palm keeps feel. Many crews size for a snug fingertip to avoid bunching on switches.
How many pairs per season
Keep one mission pair and one spare. Swap if fuel or hydraulic fluids contact the leather.
Helmet comfort and visors
Do liners change comms fit
They can improve seal and reduce hot spots. Pick the thinnest liner that stabilizes the shell without pressure on the crown.
Which tint when
Grey for bright sun and water, amber for contrast in smoke and dust, clear for night. Keep the clear ready even on bright days.
Last updated: October 7, 2025
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