Hard Core PT – with Hook & Loop Cummerbund

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.