The purpose of this is to discuss why a few dollars worth of foam and nylon are able to create a comfort zone (padding) for load bearing equipment, as well as showcase the method of installation of the mentioned material.
Starting with the padding, a closed cell foam will tend to break down less and hold its form better than its open cell sibling. Closed cell foam tends to be less flexible and provide more structure and stability, which is a long term asset. If you need heavy padding, consider two rows of closed cell foam, or one open cell and one closed cell layer. If you go with one open cell (softer) piece, use that side towards your skin and the closed cell away from yourself. Both open and closed cell foam should be available from any upholstery or fabric shop.
Eagle Industries makes the inserts which function as padding, or holders for padding. These shoulder straps come in several sizes, with some being marked as padding, and some being marked as for ballistic protection. The ballistic protection ones are larger, and open easily (with hook and loop) for padding or ballistic inserts. In this case, the larger versions won't be used for ballistic protection, they will be used to insert padding and create a more comfortable load carriage system. Ebay is a great source, and prices tend to run in the $10-$15 range.
Whether you are using a LBE (Load Bearing Equipment), LBV (Load Bearing Vest), Y or H harness, or pack, shoulder padding makes a substantial difference, especially as weight is increased. The secondary function is to aid in comfort for injuries, especially shoulder injuries.
Once you have the foam and shell, trace and outline and cutout the foam to match the shape. Scissors can be used, but a sharp knife slices through foam and works nicely as well. Remember to cut towards the large side, and trim as needed to get a tight fit.
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You will probably end up with a lot of left over foam, you can throw it out, or you can figure what the scraps can be used for. In many cases, the extra foam can be trimmed down to silence equipment in pouches, or provide extra padding on other equipment.
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