This guide is intended to help you identify the correct external carrier size when using an existing ballistic package.
Start by identifying which type of ballistic panels you currently have. The process is different for Armor Express® panels and panels made by another manufacturer.
Existing Armor Express® Ballistic Panels
If you already have Armor Express ballistic panels, you do not need to measure the panels to determine your carrier size.
Locate the four-digit sizing code on both the front and rear ballistic panels. Provide us with both codes when ordering or confirming your external carrier size.
Example:
Front Panel Size Code: XXXX
Rear Panel Size Code: XXXX
If you are unable to locate the sizing codes, send us clear photographs of the identification labels on the front and rear panels and we can assist you.
Existing Ballistic Panels From Another Manufacturer
If you are using ballistic panels from another manufacturer, the actual panels must be measured before we can recommend an Armor Express external carrier.
Remove the front and rear ballistic panels from the carrier and lay each panel completely flat on a table or other flat surface before measuring.
Do not measure the panels while they are installed in the carrier, folded, compressed, curved around the body, or being worn.
Measure the Front Panel
Width: Measure horizontally across the widest point of the ballistic panel from edge to edge.
Height: Measure vertically from the highest point of the panel to the lowest point.
Measure the Rear Panel
Width: Measure horizontally across the widest point of the rear ballistic panel from edge to edge.
Height: Measure vertically from the highest point of the rear panel to the lowest point.
Record all measurements in inches to the nearest ¼ inch.
Important: Panel width and height tell us the overall size of the ballistic package, but they do not tell the entire story. Ballistic panels from different manufacturers can have significantly different wing profiles, shoulder geometry, taper, and overall shapes even when their maximum dimensions are similar.
Ballistic Panel Compatibility
Armor Express external carriers are designed around Armor Express ballistic panel profiles. Some ballistic panels from other manufacturers may physically fit certain Armor Express carriers, while others may not.
If you intend to use another manufacturer’s ballistic panels, contact Armor Exchange before ordering so we can review the manufacturer, ballistic model, dimensions, and panel geometry.
Physical fit does not mean manufacturer approval. A ballistic panel from another manufacturer may physically fit an Armor Express carrier without the mixed-manufacturer configuration being approved, certified, validated, or endorsed by Armor Express.
Known Compatibility Issue: Safe Life Defense®
Based on our direct fitting experience with agency armor, Safe Life Defense ballistic panels are not physically compatible with the Armor Express Traverse carrier.
The issue is not simply panel width or height. Safe Life Defense ballistic panels use a substantially boxier wing profile than the more traditional ballistic geometry accommodated by the Traverse. As a result, the panels do not properly seat within the carrier even when their maximum width and height measurements appear appropriate.
Armor Exchange does not recommend forcing, folding, compressing, trimming, or otherwise modifying a ballistic panel or carrier to make an incompatible combination fit.
Final Fit Check: Body Circumference
Once you know the width of the front and rear ballistic panels, perform a final circumference check against the wearer.
Using a soft measuring tape, measure horizontally around the torso at belly-button level. Keep the measuring tape level and comfortably against the body without pulling it excessively tight.
Round the circumference measurement up to the nearest even number.
Example: If the wearer measures 41 inches around the torso, use 42 inches for the circumference cross-check.
⚠️ Fit Check: For external carriers, the combined width of your front and back panels should be at least 2 inches greater than your total body circumference.
This provides the necessary side overlap and helps ensure the carrier closes and positions properly.
Example: If the wearer’s total body circumference is 42 inches, the combined width of the front and rear ballistic panels should be at least 44 inches.
What to Send Us for a Fitment Review
If You Have Armor Express Ballistic Panels
- Front ballistic panel four-digit sizing code
- Rear ballistic panel four-digit sizing code
- Total body circumference
- Carrier model you are considering
If You Have Ballistic Panels From Another Manufacturer
- Ballistic manufacturer
- Ballistic model or package name
- Front panel maximum width
- Front panel maximum height
- Rear panel maximum width
- Rear panel maximum height
- Total body circumference
- Clear photograph of the front ballistic panel laid flat
- Clear photograph of the rear ballistic panel laid flat
- Photograph of the ballistic identification label, when available
- Current carrier manufacturer and model, if known
Contact Armor Exchange before ordering if you intend to use ballistic panels from another manufacturer or are unsure about carrier compatibility.
Armor Express® and Safe Life Defense® are trademarks of their respective owners. References to third-party products are provided solely for product identification and physical-fitment guidance and do not imply affiliation, sponsorship, or endorsement.
