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I agree. IMO, Aerostitch is pricing themselves right out of the market.
In today’s market people just want to order it up on Amazon with free shipping. If they don’t like it for any reason just send it back with no questions asked. … guaranteed for life also helps.
 
About 2 years ago I went to one of their pop-up stores in Auburn Wa. Tried on and ordered Roarcreafter 1 piece, Darien jacket, pants, the fleece liner (its amazing) and the small messenger bag. Everything came in about 5 weeks, it all fit perfectly. Best gear I've ever owned, seemless process. Sorry to hear your experience was less than outstanding.
 
I got the Roadcrafter 1pc back in 2010. I just ordered going by the guidelines on their website. The suit fit fine. I wear it every day I ride to this day. It's getting a little ratty, but still keeps me dry. I've worn it mostly in hot weather, and it can be hot. 117 degrees in Las Vegas last summer (dry heat), close to 100 degrees to Dallas, TX for hours last summer as well. I made it, and still like and wear the suit. I like the Roadcrafter, but have used the Darien Light, and Falstaff from Aerostich and those were no good for me.
I was sold on the Roadcrafter after seeing John Ryan ride the 5600 miles from Deadhorse, AK to Key West, FL in 3 1/2 days riding with one. Testimonial to how well it works.
 
I have a lot of Aerostich products and have been satisfied with them in most regards. I do wish they would have kept up with a few innovations that some of the other brands have, but it has worked for them overall I believe. I have a 14-year-old 1-piece Roadcrafter that is still my go to for daily commuting and riding. It has held up well and the ease of use is why I tend to use it the most. But for touring/trips, I have an Aerostich Transit suit. Leathers. They are treated to be waterproof and UV resistant so they don't get too hot at all and will keep you toasty with a heated shirt in the cold. This is the absolute best piece of riding gear I have ever owned. They have never let me down. Even in all day rain I have stayed dry and comfortable. They worked so well I spent the money on a suit for my wife as well. This is unfortunately some of the most expensive touring gear out there though, as a suit right now will run around $2500 after taxes and shipping. But my Transit suit is 9 years old and still going strong. Worth the money for me.

Everyone freaks out about both of my suits during the summer here in Arkansas but if you have a good base layer and set up your venting, it is better than most things out there in the summer heat. I believe that mesh gear is worse when the ambient temps are higher than your body temp, and you really need some built up sweat or water to keep you cooled down. Mesh gear just dries you out too quick and it is like sitting in a blast furnace for me. Non-mesh gear, you just have to deal with your own body heat, which seems to be better than the ambient environment at times.

The pricing of some of the more expensive gear seems to be astronomical, but as long as it does as advertised, it may be worth it. I have a friend that was also not happy with his brand-new R-3 because it was seeping water into his crotch in heavy rain. Come to find out, he did not know to make sure to position his zipper flaps as he was zipping up the flaps to keep the water that seeps through the zippers out. Even the best zippers will let some water by if given enough of a chance. Once that was figured out, problem solved. Eventually as they age, they need to be treated and everything but I have seen suits that are 20 years old still chugging along.

In the end, I am still paying attention to other gear, because if somebody can figure out how to get things to be better for a small cost, it would definitely be worth getting some new gear...
 
The sizing is a bit of a pain. When I had my Roadcrafter down, I too had gone through a process of measurements, but they nailed what I wanted on the first whack. If I were to buy another suit tomorrow, I would fly to Duluth and get measured in house though. I bought my Transit Suit during the clearance of the Transit II suits that were left in stock and they just happened to have my size, but I needed to change my jacket from long to regular, and the swap only took about a week there and back. They sent the other jacket out at the same time I sent the one I had back, no questions asked. If I were to buy another suit tomorrow, I would get measured in house though. It is hard sometimes to get off the rack stuff to fit the way you want.
 
The sizing is a bit of a pain. When I had my Roadcrafter down, I too had gone through a process of measurements, but they nailed what I wanted on the first whack. If I were to buy another suit tomorrow, I would fly to Duluth and get measured in house though. I bought my Transit Suit during the clearance of the Transit II suits that were left in stock and they just happened to have my size, but I needed to change my jacket from long to regular, and the swap only took about a week there and back. They sent the other jacket out at the same time I sent the one I had back, no questions asked. If I were to buy another suit tomorrow, I would get measured in house though. It is hard sometimes to get off the rack stuff to fit the way you want.
Preach it @jwmead72 ! I used to wear mesh jackets and just could not ride long distances in our Texas Summer temperatures. That "cooling breeze" that the mesh gear provided became a blast furnace. I eventually listened to long-distance Iron Butt riders and tried a heavy textile jacket. The difference was amazing, for the exact reasons you mentioned. I transitioned to MotoPort textile gear and can ride dawn to dusk in 100Âş F. weather.

Glen
 
Above 93-95F you can’t drink enough water fast enough to stay net ahead of dehydration. It’s best to get out of mesh and cover exposed skin and manage ventilation through the vents. The 1 piece RC suit has been very effective and versatile for me, handling mid 30s to 100+ temps. I live in Florida but my riding area is the lower tier of the US. One (of two in 19 years) had to be returned for wrong sizing but it didn’t take long. This past year I added a Darien jacket to a pair of Darien pants I bought about 5 years ago. All my dealings with Aerostich have been pleasant.
 
Everyone freaks out about both of my suits during the summer here in Arkansas but if you have a base layer and set up your venting, it is better than most things out there in the summer heat. I believe that mesh gear is worse when the ambient temps are higher than your body temp, and you really need some built up sweat or water to keep you cooled down. Mesh gear just dries you out to quick and it is like sitting in a blast furnace for me. Non-mesh gear, you just have to deal with your own body heat, which seems to be better than the ambient environment at times.
I had another friend with a Roadcrafter and he loved it. I tried it one hot summer day and even with all the vents open I could not wear it! I baked in it. I have worn mesh in 120F heat and yes it was hot, but I felt cooler than I did in the Roadcrafter. I might survive while moving, but stopped in traffic I was dying. I don't know how anyone can wear one in the heat!

I have long sleeve t-shirts, similar to Under Armour that I will wear under my mesh in hot weather. Another thing is I don't wear typical t-shirts when it gets that hot. Again, more Under Armour style, breathable t-shirts, but short sleeve. The typical rally and motorcycle tees are terribly hot.
 
I prefer the fit of the AD1 pants over Darien.

As a tall guy I never had a set of coveralls that fit me. Always clam diggers and/or had me sing like a choir boy. I didn't give the Roadcrafter 1 piece the look it deserved. I went to one of their road shows and got measured and saw how one could work -- the torso length is the base measure, so I needed a larger one then taken in a few places (less so now). If I crash what I've got I may go back that way.
 
I had another friend with a Roadcrafter and he loved it. I tried it one hot summer day and even with all the vents open I could not wear it! I baked in it. I have worn mesh in 120F heat and yes it was hot, but I felt cooler than I did in the Roadcrafter. I might survive while moving, but stopped in traffic I was dying. I don't know how anyone can wear one in the heat!

I have long sleeve t-shirts, similar to Under Armour that I will wear under my mesh in hot weather. Another thing is I don't wear typical t-shirts when it gets that hot. Again, more Under Armour style, breathable t-shirts, but short sleeve. The typical rally and motorcycle tees are terribly hot.
I understand your experience is good for you but science of body cooling is not on your side. I don’t think I could wear the 1 piece in hot stop n go traffic either. It has to have air movement through it in 85+F up. I have mesh gear too and depending on which bike I’m riding from naked to fully faired the ambient temperature impacts what I pack or pull out of the closet.
 
IME the only place mesh outperforms textile for comfort is 80s & 90s, higher humidity. Moreso at slower speeds. Unfortunately, that's the bulk of the summer here in the mid-Atlantic and many places.

I wore a mesh jacket for comfort on a week's ride in WV some years back. It wore a bit cooler than my Darien would have, but it fared poorly when I crash-tested it. It wasn't a lousy jacket, just an OK one.

I gave up wearing mesh jackets after that for a while. But when I started working bicycle races and rides, going slow in the heat, I went back to one. I hope I don't crash test it but I spent some money for a more protective jacket: Klim Baja S4. Only CE 1 armor in it at the moment (added a back pad) but the jacket is rated CE AA meaning it won't fall apart like the other did so at least the armor may stay where it belongs. Fingers crossed.
 
I've bought 2 roadcrafters and one pair of AD-1 pants. My first roadcrafter was bought in 2009. I did manage to rip a pocket in the lining for a knee pad and had to sew it up. Otherwise it has a good 100k plus miles on it and is fine. A couple of the pads could use a freshening up. I upgraded to a newer suit in 2021. My old one mysteriously had shrunk a bit in the middle. I ended up buying the new one with an extra couple inches in the middle. THe unlined R3 is an improvement over the lined classic.

For my first suit, it took like 6 weeks and they sent one out and it was too short between crotch and shoulders. Sent it back and had a good fitting suit in a couple weeks. One of the things that led to my original suit shrinking, besides a few extra pounds in my mid section was that I bought one of their back pads and put it in my suit.

Overall, they have been my go to for over a decade. I have other gear and it just doesn't get used. It does take a bit as you have to get slotted into their production schedule. You are buying a bespoke garment.
 
I dont own an aerostich but i do own a langlitz, also a custom made to measure jacket. I hate to say it, but thats just what it is with a high quality in demand product. Langlits is at like a year wait, wesco boots are around 2 years. Anything special made like that has a long wait. Id say, if the sizing is what you want, put the order in and wait. It stinks, but you wont get around it in any way.
 
I understand your experience is good for you but science of body cooling is not on your side.
Yep, I know that! I tried a Roadcrafter in hot weather, out on the open road and was miserable.
I have ridden a fair amount in over 100F weather and I have figured out what works for me, and it isn't a Roadcrafter. A couple years ago we spent 3 weeks in Utah and it was over 100F every day. We spent a week on Texas in July and highs most days were 110F. Mesh jacket and Under Armour long sleeve t-shirts worked for me.
 
I prefer the fit of the AD1 pants over Darien.

As a tall guy I never had a set of coveralls that fit me. Always clam diggers and/or had me sing like a choir boy. I didn't give the Roadcrafter 1 piece the look it deserved. I went to one of their road shows and got measured and saw how one could work -- the torso length is the base measure, so I needed a larger one then taken in a few places (less so now). If I crash what I've got I may go back that way.
Love my AD1’s! They are as comfortable as a pair of jeans! I get the long so they cover my boots seated.

Image
 
My AD1 knee pads hang so far below my knees they are shin guards. They are made for somebody with 6'8" legs and I'm 5'11". That's the danger of buying off the rack sizing.
 
My AD1 knee pads hang so far below my knees they are shin guards. They are made for somebody with 6'8" legs and I'm 5'11". That's the danger of buying off the rack sizing.
You can get velcro from them to reposition your knee pads. My latest pair of Darien pants have a long strip of velcro in the knee area rather than the small patches of velcro they used on my previous pair.
 
Preach it @jwmead72 ! I used to wear mesh jackets and just could not ride long distances in our Texas Summer temperatures. That "cooling breeze" that the mesh gear provided became a blast furnace. I eventually listened to long-distance Iron Butt riders and tried a heavy textile jacket. The difference was amazing, for the exact reasons you mentioned. I transitioned to MotoPort textile gear and can ride dawn to dusk in 100Âş F. weather.

Glen
Another thing to think about in regards to the R-3 suit that this reminded me of. The R-3 does not have a liner in it, and if you are in stop and go traffic, you essentially do not have any insulation between you and the shell of the suit. ANYTHING in direct summer sunlight will get really hot, and without any insulation, that heat transfers directly from the shell, to your skin. For you folks that have difficulty with the summer heat and your gear, was there enough insulation to absorb it, if any at all? Anybody that has seen the classic Roadcrafter or other comparable gear will see that it has that insulating "inner liner" in them that will insulate you from the outer shell, and all the direct sunlight it is taking.
 
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