Navy Seal Breaks Down Our Kit (Plate Carrier & Belt)

Intro and Jim Foreman’s Background

The hosts introduce retired Navy SEAL Jim Foreman to discuss practical setup of plate carriers and battle belts. Jim explains that he spent 27 years in the SEAL teams and now works at Ferro Concepts, a tactical gear company known for rapid innovation and responsiveness to user requirements. He notes that their gear comes in multiple colors and patterns and is widely used by government units. The hosts mention that viewers frequently ask how to configure plate carriers, and they want Jim’s perspective as someone who has worn them operationally for years. They place a camera operator’s plate carrier on the table and ask Jim to critique its configuration and suggest improvements for a more functional, realistic loadout.

Breaking Down an Overloaded Level IV Plate Carrier

Jim examines the first plate carrier and immediately notes that it is set up for “everything,” which makes it very heavy and cumbersome. It uses level IV plates weighing about 8 pounds each, adding roughly 16 pounds before any pouches or accessories. Jim prefers plates around 3 pounds or less to maintain mobility. He points out that many of the pouches are loosely mounted: a pistol mag pouch on the front rotates and could spill contents when running or crawling, and MOLLE straps are not fully woven, creating slack and pockets where gear can flop and rattle. The rear backpack is also loosely attached, leaving a gap that allows it to swing and make noise. Jim argues that much of this extra gear should move to the belt or a pack, and that three rifle magazines on the front plus one in the rifle—about 120 rounds—is usually sufficient on the carrier itself.

Minimalist Ferro Concepts FCPC Setup

To illustrate his preferred approach, Jim shows his Ferro Concepts FCPC plate carrier. The front is kept very light, with three rifle magazines and no additional stacked pouches. A radio pouch rides on the side and can also hold extra magazines if needed. The cummerbund is tight and uses lightweight but rigid Tegris, a carbon fiber-based material, to support side plates and a small pouch for items like night vision or gloves. The shoulder pads are intentionally minimalist compared to thick, bulky pads that trap sweat and water. On the back, he runs a Ferro Concepts backpack that zips directly to the carrier and is further secured with Tegris MOLLE at the top and bottom, eliminating flop and noise. Because the pack is thin and rigidly attached, he can leave it on even when empty without adding much bulk, maintaining a slim profile compared to the earlier, overbuilt setup.

Lightweight Plates and Maritime Considerations

The hosts comment on how light Jim’s carrier feels, and he explains that it uses plates from Tacticon-style manufacturers such as Tac 11. His current plates are rated at level III+ and weigh just over 3 pounds each, making the entire system significantly lighter than the earlier level IV setup. He also describes another Tac 11 plate, the Fixer Bravo, a level III++ plate that stops .30-06 rounds, is about 1 inch thick, and actually floats. Jim notes that floating plates are valuable for maritime units. In water, heavy, absorbent gear can turn the wearer into an anchor, so teams add closed-cell foam behind plates to achieve neutral buoyancy. A plate that floats reduces the amount of flotation material needed, helping the swimmer remain neutral when entering the water with a weapon, belt, and full kit, and reducing reliance on separate life preservers during maritime operations.

Evaluating a Second Heavy Plate Carrier

Jim then evaluates a second plate carrier belonging to another camera operator. This carrier is wider on him and set up with four rifle magazines across the front, plus additional pouches including two pistol magazine pouches. Jim states that, outside of specific vehicle work, he prefers to keep pistol magazines on the belt and reserve the chest for rifle support gear. Again, the plates are level IV, providing strong protection but adding substantial weight. On the back, this carrier uses a zip-on backpack system with a large compartment suitable for tools or breaching charges, but it is bulkier and wider than the Ferro Concepts pack. Jim notes that if he did not need the storage, he would remove this backpack entirely, whereas the slimmer Ferro Concepts pack can stay attached without getting in the way. He also observes extra slack in the front adjustment, leaving about an inch of unused material that could be tightened to bring the carrier closer to the body.

Swappable Front Panels and Managing Chest-Borne Gear

The discussion shifts to stacking gear on the front of the carrier. One host dislikes adding anything over rifle magazines because it increases profile. Jim acknowledges that stacking is possible but prefers modularity. He shows a Rhodesian-style placard that attaches with Fastex buckles and compares it to a Ferro Concepts front panel that uses G-hooks and Velcro. His FCPC normally runs a simple three-magazine panel, but he can quickly swap to a different panel that still holds three rifle magazines while adding a zippered compartment and two pistol magazine pouches. He typically uses those pistol pouches for a multitool or flashlight rather than extra pistol mags. This approach keeps the front panel thin and low profile while allowing configuration changes for different tasks, instead of permanently stacking bulky pouches on top of rifle magazines.