Here's How REV'IT! Makes MotoGP Racing Leathers. And It Takes 23 Measurements

If you love a good behind-the-scenes process video as much as I do, then you're in for a treat today. Former BSB racer Taylor Mackenzie still loves to ride as much as he ever did, and he recently took a tour of the REV'IT! Tailortech facility in Italy to get measured and fitted for a new set of custom racing leathers. But rather than snap a few photos and a clip or two to share on his Instagram, he instead brought us all along for the ride with this video.

Now, if you're a person who sews at all, then you may have at least some small idea of what's involved in undertaking a garment as complex as a race suit. It surely helps, in REV'IT!'s case, that it only currently offers three different race suit types through its Tailortech made-to-measure program. While the measurements will of course differ based on each person who's getting a custom suit made, the configuration of the different pieces needed to complete each suit is predetermined by which pattern is being used.

Just how many measurements are we talking about? A total of 23 separate measurements are taken by REV'IT!'s experts, to ensure that each custom suit fits a given rider precisely. That includes ensuring that the necessary stretch panels are doing their job perfectly, so the suit is well-fitted and protective, but so that the rider can move themselves around on (and off) the bike as necessary to ride well. 

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The entire process is fascinating, from measurements and full body scanning (yes, really) to make sure everything is as precise as possible. After all the measurements are taken and confirmed, all the pattern pieces are laid out in software, and any graphic design elements (think all the sponsor logos you see on most race suits, as well as racer names and number graphics) are laid out digitally as well. 

After all the measurements and layout are checked (again) and approved, the pattern is laser projected onto massive sheets of leather, which are then cut out with great precision by special cutting machines. If you've ever painstakingly cut out a zillion pattern pieces by hand, you can surely appreciate the intricacies involved here.

How do all those logos get onto the leather with such precision, you might be wondering? Guys, they're printed. PRINTED! The whole video is extremely cool to see, but this part may just blow your mind. If you think printing is only for paper, photos, and maybe 3D motorcycles (and parts), that's apparently not the case!

This is kind of what I love about this process, though: All the important stuff, the stuff that really matters? It's all done by hand. A series of skilled seamstresses (say that three times fast) each has a part to play in sewing each suit together by hand, then doing quality control checks, and also installing all the armor/speed hump/airbag before each suit heads off to its proud new owner.

Cherish your craftspeople, because they're who will continually save your skin. 

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