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I currently ride my KLR while wearing an armored jacket, gloves and helmet. But my lower body is still vulnerable since I wear tactical cargo pants and composite-toe leather work boots.

Saving my pennies for some good boots and thought I'd look for ADV pants. Holy cow! I went to Rocky Mountain ATV and the only pair they had close to my size was $289. I am 6'2" and 300lbs with a 46" waist.

Since I ride almost exclusively in dry weather, all I need is something that is comfortable and has the added protection. I have a pair of Frog Togs for throwing on if it rains.

I am dating a professional seamstress/paralegal/pianist/former marathoner (she is amazing) and am thinking about seeing if she could just take a pair of my rip-stop tactical pants and add some abrasion panels and pockets for knee pads.

She could make me a pair of custom pants since she does have gore-tex, rip-stop, and other high-end materials on hand. But, I am losing weight and don't want to ask her for such a huge project if I will be 80 lbs skinnier next year.

If I were to have her modify a pair of rip-stop cargo pants, what features do you all think are important for riding in the woods?
 

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2002 KLR 650
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These pants are well liked by frugal riders. No 46 waist sizes, but maybe she could do a fastener extender and add a wider zipper ? Probably cheaper than buying material. Shoot, I rode in carhartts for a long time. They would most likely ignite on a pavement crash though.
 

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2002 gen 1 street-ized commuter special--Flatland Flyer--
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i would recommend spending money on a good pair of riding boots to protect you lower legs and ankles too.
 
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2018
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These pants are well liked by frugal riders. No 46 waist sizes, but maybe she could do a fastener extender and add a wider zipper ? Probably cheaper than buying material. Shoot, I rode in carhartts for a long time. They would most likely ignite on a pavement crash though.
I have a set of HWK for summer and they are very nice for the money.
 

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2022 Kawasaki KLR 650
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One feature I REALLY like are full leg zippers. Unfortunately, I've never seen any motorcycle pants like this. I have insulated ski pants for winter and Marmot GoreTex rain pants (for backpacking/climbing, etc) for summer, both with full leg zippers. That lets me put them on and take them off without even lifting my feet off the ground so boots aren't an issue. Has anyone seen any motorcycle pants with this feature?
 

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Think snowmobile pants. They are also bibbed so they keep your upper body warm as well.
 

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2022 Kawasaki KLR 650
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Think snowmobile pants. They are also bibbed so they keep your upper body warm as well.
Yup. Already did that a few years ago when I found what looked like a ski bib with "Yamaha" stitched on it. I used it for years, but it did didn't have full leg zippers. Almost did so it was still pretty easy to get into, but I had to lift feet and maneuver around wet/muddy boots sometimes. That thing was so warm I had to put it on right before I went outside or I'd be sweating to death. It didn't pack down very well. I also melted one leg on the exhaust on my TransAlp.
 
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One feature I REALLY like are full leg zippers. Unfortunately, I've never seen any motorcycle pants like this. I have insulated ski pants for winter and Marmot GoreTex rain pants (for backpacking/climbing, etc) for summer, both with full leg zippers. That lets me put them on and take them off without even lifting my feet off the ground so boots aren't an issue. Has anyone seen any motorcycle pants with this feature?
of my Olympia pants have had full-length zippers. The last pair I bought were the Newports, which I think are still current, and they have full-length zippers.
 
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Most pants listed as "overpants" will have full length side zippers.

I had a set of olympia mesh overpants for awhile. Convenient, but I found them very baggy. I now run a set of (discontinued) Fieldsheer Phantom overpants. Much slimmer.

I wouldn't rely on cargo pants for any kind of street abrasion resistance. Normal pants have nowhere near the structural integrity and abrasion resistance of a set of proper riding pants. Riding pants are ideally built with abrasion resistant materials like Cordura and other high denier nylon or nylon blends. The seams are double stitched, and sometimes the really abrasion prone areas have another layer of higher grade material sewed over the top.

Check out your local classifieds. People are upgrading their gear all the time, or clearing out their closet.
 

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2022 Kawasaki KLR 650
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of my Olympia pants have had full-length zippers. The last pair I bought were the Newports, which I think are still current, and they have full-length zippers.
Thanks for the tip on the Olympia Newports. Looks like most vendors are sold out, and I still have life left in my current Marmot pants and ski pants. I will be stalking clearance sales for these. It would be nice to have pants made for motorcycling with abrasion resistance and specific fit instead of hijacking ski/backpacking clothes.
 

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2016 Gen 2 Camo
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Before I got riding pants, I used carhart overalls, double walled knees and have a picker to insert knee pads. I had them when I started riding again, so I used them until I got real gear. There is no substitute for purpose made PPE.
 
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