Rothco Military-Style Flightsuit Coverall

The Rothco Military-Style Flightsuit is a full-length men's coverall cut from a 55% cotton / 45% polyester blend, designed for pilots, aircrew-role players, and anyone who needs a durable one-piece work or field garment. Eight pockets and a full suite of fit-adjustment features make it functional across a wide range of uses. Available in Black, Woodland Camo, Olive Drab, Foliage Green, Khaki, Navy Blue, and Orange, in sizes XS through 7XL depending on color.

Built for a Full Day of Wear

The 55% cotton / 45% polyester fabric balances breathability with durability: cotton keeps the suit comfortable against the skin during extended wear, while the polyester content adds shape retention and resistance to abrasion. Underarm vents provide active airflow, which matters when a coverall is worn over a base layer or in warm conditions. Reinforced shoulders add longevity at the points of highest stress without adding meaningful bulk.

Eight Pockets, Organized Storage

The Rothco Flightsuit carries eight pockets in total: two zippered slash chest pockets, a zippered utility pocket with a dedicated pen holder on the left sleeve, four zippered leg storage pockets, and one snap-button accessory pouch. That distribution keeps frequently needed items at chest level and bulkier gear lower on the legs, so the suit stays balanced when loaded.

Fit Adjustments and Easy On/Off

A two-way front zipper lets the wearer open the suit from the top or the bottom, which is useful when seated for long periods. Adjustable waist tabs allow the fit to be dialed in without removing the suit, and hook-and-loop wrist cuffs can be tightened to keep sleeves in place. Bottom leg zippers make the suit easy to pull on and off over boots without unlacing them.

Patch and Name Tape Ready

A hook-and-loop badge holder and a left chest loop field accept standard name tape, flag patches, and morale patches without any modification. The suit ships without patches or insignia, so the wearer configures it to their own specification.

Features

  • Fabric: 55% cotton / 45% polyester blend with underarm vents for airflow
  • Storage: 8 pockets total (2 zippered chest, 1 zippered sleeve utility with pen holder, 4 zippered leg, 1 snap-button accessory pouch)
  • Closure system: Two-way front zipper, bottom leg zippers, hook-and-loop wrist cuffs
  • Fit adjustment: Adjustable waist tabs for a tailored fit without removal
  • Customization: Hook-and-loop badge holder and left chest loop field for patches and name tape
  • Durability: Reinforced shoulders at high-stress points

Specifications

Specification Detail
Material 55% Cotton / 45% Polyester
Pockets 8 (2 zippered chest, 1 zippered sleeve utility with pen holder, 4 zippered leg, 1 snap-button pouch)
Sleeve type Long sleeve
Closure Two-way front zipper; bottom leg zippers; hook-and-loop wrist cuffs
Fit adjustment Adjustable waist tabs
Ventilation Underarm vents
Customization Hook-and-loop badge holder; left chest loop field
Reinforcement Reinforced shoulders
Gender Men's (adult)
Colors available Black, Woodland Camo, Olive Drab, Foliage Green, Khaki, Navy Blue, Orange
Sizes available XS–7XL (range varies by color; see variant selector)
Approximate weight (XS–XL) 1.60–1.70 lb depending on color
Approximate weight (2XL–3XL) 1.70–1.90 lb depending on color
Approximate weight (4XL–7XL) 1.85–2.20 lb depending on color
Origin China

Who This Is For and Isn't

The Rothco Flightsuit suits pilots, ground crew, airsoft and milsim participants, security and law enforcement personnel who want a one-piece duty garment, and costume or reenactment use where an authentic aviation coverall silhouette is needed. The extended size run (to 7XL in Black, to 5XL in Khaki) accommodates a wide range of builds.

The Rothco Flightsuit is a textile garment with no ballistic, stab, or cut protection of any kind. It is not rated to any NIJ or other protective standard. Buyers seeking body armor or protective outerwear should look at separate protective products. The size range varies by color; not every size is available in every colorway.

Common Questions

What is the fabric composition of the Rothco Flightsuit?

The Rothco Flightsuit is made from a 55% cotton / 45% polyester blend. The cotton content provides comfort against the skin during extended wear, while the polyester adds shape retention and abrasion resistance. Underarm vents are built in to improve airflow when the suit is worn over a base layer.

How many pockets does the Rothco Flightsuit have, and where are they?

The Rothco Flightsuit has eight pockets: two zippered slash chest pockets, one zippered utility pocket with a pen holder on the left sleeve, four zippered leg storage pockets, and one snap-button accessory pouch. All closures on the storage pockets are zippered except the accessory pouch, which uses a snap button.

How does the fit adjustment system work on this flightsuit?

The Rothco Flightsuit uses adjustable waist tabs to tailor the fit around the midsection without removing the suit. Hook-and-loop wrist cuffs can be tightened or loosened at the sleeve ends. A two-way front zipper allows the suit to be opened from the top or bottom, and bottom leg zippers make it easy to pull on and off over boots.

Can patches and name tape be added to the Rothco Flightsuit?

The Rothco Flightsuit includes a hook-and-loop badge holder and a left chest loop field that accept standard name tape, flag patches, and morale patches without modification. No patches or insignia are included; the suit ships plain and the wearer adds their own.

Does the Rothco Flightsuit offer any ballistic or protective rating?

The Rothco Flightsuit is a textile coverall with no ballistic, stab, or cut-resistance rating. It is not certified to any NIJ or other protective standard and should not be used or selected as protective equipment against physical threats.

What sizes and colors are available, and do all sizes come in every color?

The Rothco Flightsuit is available in Black (XS–7XL), Woodland Camo (S–2XL), Olive Drab (XS–4XL), Foliage Green (S, M, XL, 2XL), Khaki (XS–5XL), Navy Blue (XS–3XL), and Orange (S, M, 2XL, 3XL). Size availability varies by color; use the variant selector to confirm which combinations are in stock.

Bulletproof Zone will ship orders as soon as possible. For example, if you purchase three items, they will be shipped to you based on lead time and availability. This way you get as much of your order as soon as possible, which means that your order may come in separate packages, especially if you order products from different manufacturers.

We will bear the shipping cost for products returned because of product defect, misrepresentation, or false description. Afterward, we will initiate a full reimbursement should you decline an offer to replace the item with the same item of equal value and assured quality.

Order Confirmation:

As soon as you place your order with Bulletproof Zone, you will receive an order confirmation e-mail. This means that your order has been logged in our system and your credit card has been pre-authorized for the purchase. Afterward, we contact our suppliers to confirm the availability of the product you are ordering for immediate shipment. If your item is on backorder or unavailable, we will cancel the pre-authorization and duly inform you via e-mail.

Order Shipment:

Orders are shipped within five business days from the date of your order unless specified otherwise on the product page. The product page will contain the most accurate estimate on shipping and lead times. Shipping and lead times provided on the product page are our best estimates based various factors including order volume, information from our manufacturer, raw material fluctuations, etc., and may vary due to these factors. 

You will receive an email containing the tracking information of your order after the order has been shipped to your location. If you do not receive tracking information from us within seven business days of the lead time specified on the product page, feel free to follow up with us at orders@bulletproofzone.com.

Bulletproof Zone is not responsible for lost or stolen packages. A tracking number will be provided when the package is shipped. It is the buyer’s responsibility to provide a safe place to receive mail. Once an item has been marked as delivered by the carrier, the seller is not responsible should that item go missing. 

Some of our products are carried by manufacturers in various countries. Due to the nature and cost of the products that Bulletproof Zone sells, you may be charged additional import duties upon delivery. Our support team can help in investigating abnormally high import duty charges but we are unable to cover the cost of any import duties.

Damages:

We take full responsibility for any obvious damage to your product caused by wrong packaging or delivering an already defective product. Please inspect the packaging of your item(s) when they arrive, if you notice any damage, you should document it when signing for delivery. If the item(s) contained in the package arrives damaged, please send photos to support@bulletproofzone.com, and we will process an insurance claim on your behalf. 

Returns and Cancellation Policy:

We back all our products with a customer satisfaction guarantee, so we created a fair return and cancellation policy.

All sales are final. No Refunds, No Cancellations. In most cases, once the order is processed, it is final and not cancellable. We may allow exceptions due to an order error or wish to return your order after delivery for any reason other than a product defect or misrepresentation. Any cancellation request is subject to an administration and cancellation fee equal to 10% of your order with a minimum of $35, whether order shipment is successful or not. 

All sales are final on all closeout items and for custom manufactured bulletproof clothing once the manufacturing process has begun or not returnable unless there is a product defect or misrepresentation. Applicable to brands such as MC Armor, Israel Catalog, BulletBlocker, Tacticon Armament, Wonder Hoodie, and others. 

Before returning any product, you MUST obtain a return authorization from our customer service representative. We can only process AUTHORIZED returns for items.

To make a Return or Exchange: 
  • Obtain authorization for return or exchange by emailing us at support@bulletproofzone.com explaining the reason for the return or exchange.
  • Please use or indicate your order number as attention

Return or exchanges request submission must be within 14 calendar days upon receipt of shipment unless noted otherwise on the product description page.  Your return must be in original packaging and unused.

We encourage using USPS flat-rate shipping in returning products to receive a shipping expense refund. Buyers must ensure all returned parcels delivery receipt AND signature confirmation. We highly recommend insuring your parcel as we cannot issue a refund for an item that we do not receive back should it get lost/damaged during transit.

Refunds:

Should an item be returned because it was defective, misrepresented, not as described, etc., Bulletproof Zone will issue a full refund and will reimburse the customer for all shipping expenses associated with the return.

Please allow 5-10 business days from the time the item is received to process a refund. Refunds will only be issued to the original credit card that you use when placing your order.

We stand behind our products 100%!

By purchasing any of our items, the buyer certifies they have read and agree to our shipping, return, and privacy policies.

The Bulletproof Zone Promise

When you buy body armor, you're buying your safety. We don't take that lightly. Here's what every order from Bulletproof Zone includes.

1. Authorized dealer of every brand we carry

Every plate, vest, and carrier we ship comes from the manufacturer directly to our warehouse. We don't sell gray-market product, surplus, or returns. That means factory-fresh stock, the full manufacturer warranty, and real after-sale support — the kind only an authorized dealer can offer.

We maintain authorized-dealer relationships with America's leading body armor brands, including Spartan Armor Systems, AR500 Armor, RMA Defense, Shellback Tactical, Caliber Armor, DFNDR Armor, Protection Group Denmark, BulletSafe, BulletBlocker, and over 40 more.

2. Best price, guaranteed

If you find a lower price at another authorized dealer of the same product within six months of your purchase, we'll refund the difference.

Why the "authorized dealer" requirement? Because gray-market and surplus armor may not be genuine, may have a compromised supply chain, and almost never comes with a manufacturer warranty. We won't price-match against products that may not actually protect you.

3. Free fitment consultation

Body armor only protects you if it fits. Email us a photo and your measurements before you order, and one of our specialists will help you size your carrier and plates correctly — at no charge, no obligation.

4. Trusted by thousands of customers

Bulletproof Zone has been a trusted authorized dealer of America's leading body armor manufacturers for over five years. We have over 4,000 verified Trustpilot reviews from real customers across all 50 states.

Price Match Guarantee — Terms

  • You must have purchased the item from our website before requesting the price match.
  • Discounted items and "free with purchase" items are not eligible.
  • The item must be in stock on the competitor's website at the time of your request.
  • The price match is valid for six months from the date of your purchase.
  • The competitor must be an authorized dealer of the product. Auction sites (eBay, Overstock), discounters, and gray-market resellers do not qualify.
  • The competitor must operate an online store. Brick-and-mortar-only retailers do not qualify.
  • Price match applies to the item price plus shipping. Sales tax is excluded.

To request a price match, email us a link to the product on our site and the same product on the competitor's site within six months of purchase. We'll process the refund.

Why Bulletproof Zone?

At Bulletproof Zone, we are passionate about protecting lives. Every piece from our catalog is designed and rigorously tested to provide the highest quality of protection you need from firearms, explosives or even close quarters combat.

We’ve partnered with various manufacturers that operate within the United States under a strict set of guidelines both on a national and corporate level so that when you shop with us, you will be able to select from the highest quality body armor, ballistic plates and tactical gear available on the market.

Whether you are a military service member looking to find your own gear, a professional that operates in the security field, or an avid firearms enthusiast that capitalizes the importance of safety when shooting, our tactical gear will provide you the level of protection you need.

Any questions or concerns? Please call us at (408)-909-4938 or email us at support@bulletproofzone.com and a member of our professional support team will be in touch with you as soon as possible.

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