Minimum 2-layer, maximum 3-layer
Overalls used in motorsport are made of at least 2 and at most 3 layers of flame-retardant material, usually Nomex or a derivative thereof. The 3-layer overalls are the best performing and most comfortable overalls. To meet the FIA requirement with 2 layers, relatively thick layers must be used.
In the case of a 3-layer overall, the layers can be thinner, as the space between the layers also has a positive effect on the flame-retardant properties. Besides the number of layers, the major differences in the overalls are in wearing comfort and breathability. For example, the more expensive overalls often have fully inserted sleeves and various stretch panels, which provide perfect freedom of movement. The materials used in the better overalls are often extra breathable, so the warm air and perspiration moisture are much more easily dissipated compared to cheaper (2-layer) overalls. This is absolutely desirable as it almost always gets extremely hot in a race car, even in winter! The fit of the more expensive overalls is generally more tailored compared to the cheaper overalls.
The brand Sparco has introduced a fabric called Hocotex to the market in recent years. This is a combination of multiple layers compressed into 1 layer. The properties of overalls made of Hocotex material are comparable to the better 3-layer overalls.
In addition to standard sizes and designs, it is also possible with most brands to have an overall custom-made, possibly in your own design and colors. To get a better idea of the possibilities in this regard, you can check our Special Made page.
The sizing of race overalls is different from, for example, suit sizes. There are even differences between the brands themselves and in some cases between the overalls of one brand. To determine the right size, fitting is the best option, but if you are not able to do so, it is possible to make an estimate by measuring a few sizes.
The lifespan of an overall depends on several factors. It is recommended to replace an overall after 3 years of frequent use, as the fibers of the flame-retardant material wear out due to use and cleaning. As a result, the overall may no longer provide the necessary safety. For hobby use, the lifespan of a racing overall is approximately 5 to 7 years.
Overalls must comply with the FIA Standard 8856-2000 or 8856-2018.
Overalls are often provided with advertisements such as sponsor logos, website URLs, or the name of the team or the driver themselves. This can be done in the following ways:
By embroidery
Applying embroidery to an overall is only allowed on the outer layer of the overall and can therefore only be done ex-factory. With overalls with the FIA Standard 8856-2000, it is possible to have a badge made and attach it afterwards with a single stitch to the overall, provided both the badge and the thread for attachment are flame-retardant.
Although embroidery looks nice, there are also disadvantages associated with it. For each advertisement, a so-called embroidery program must be created; a digital file that tells the embroidery machine where to place a stitch. These embroidery programs are quite expensive to create and are only limitedly scalable. Using the same embroidery program for a logo on the chest (e.g., 12x12 cm) as for a large logo on the back (e.g., 25x25 cm) is therefore not possible, and the embroidery program will need to be adjusted. Additionally, the overall becomes quite stiff where the embroidery is located, and the embroidery makes the overall heavier.
Printing Methods
Nowadays, printing on a coverall is the most commonly used method for applying advertisements. The advantage of printing is that it is cheaper than embroidery, the coverall remains flexible, and the weight increases only marginally. For coveralls with the FIA Standard 8856-2000, printing afterward is relatively easy to achieve, provided the correct films for printing are used and the application is done correctly. However, due to new FIA regulations, printing on coveralls with the FIA Standard 8856-2018 is much more complicated. For coveralls with this homologation, the FIA transfer sheets must be purchased, and only 5 companies worldwide are allowed to print the coveralls afterward. After printing the coverall, photos must be taken, and an FIA passport must be requested, in which both the numbers of the transfer sheets and the photos must be included. This passport must be shown at all times when the coverall is worn. As previously mentioned, this is very complicated, and besides being possible in only a limited number of places, it is also very expensive.
When a coverall is ordered from the factory with prints, a QR code is embedded in the coverall that links to the passport. Additionally, it is significantly cheaper than printing afterward.
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Note! This guide takes into account the basic regulations as determined by the FIA.
Always check the regulations of the organization/event you wish to participate in for any deviations.