This thread should really be in mature riders - not money saving. So I should copy this there.
I too have an old style airoware. It is a Zippa.
First question is how old yours is? Airowear informed our retailer on the phone while I was there that a body protector should last about five years.
If yours is much less than this, you can order a new cover for it from Airowear, but one needs to do this via a retailer, either a local shop or an on line place will do.
My bp is only a couple of years old so I am going to order a new cover myself. I have done this before and recommend it. You can also ask to have it posted direct to your home address.
Now the problem. The standard for bps changed in 2009 - so from July 2011 Airowear wont be making their old Zippa any more.
I too find the new Airowear model - the Outline -, bulky and uncomfortable under the arms. I tried on every possible size. Airowear told me that could be because the new standard requires the arm holes to be smaller than previously - which isnt good news for those of us with narrow shoulders who wear bps for hacking.
True that you and I dont need a British Standard bp for hacking, but the manufacturers stop making anything that isnt standard.
I bought my grand daughter a new style Outline last week and she is very happy with it. The foam is softer, and it fits better than the tabbard type she wore before. This is her third Airowear bp.
But like you, I am not sorted out and OH's bp is getting old - So yes, the answer is to go to a really big store like Robinsons or Rideaway, or several smaller shops and deliberately try on half a dozen brands to find one that fits. Beware though - whatever the single brand retailer says, no brand really fits absolutely everyone.
It is a great advantage having had a body protector one likes, as by now I know I like one with a zip up the front and separate fastenings at bust and waist.
My previous one was a Champion but then for a time they did little choice of length. Now, as has been noticed, there are many new bps on the market and many of the top brands now make a vast choice of sizes.
If you want to be rid of the bulk altogether, there are the inflatable types to consider - but I am an RS rider and as I said before, have postponed that.