Army Navy Outdoors: Surplus vs Reproduction, BDU Sizing and Getting Boots to Fit

Army Navy Outdoors sells the working end of outdoor clothing: military surplus, reproduction field jackets, tactical trousers, boots, packs, wool blankets, canteens and camping kit from brands such as Rothco, Propper, Tru-Spec and Alpha Industries. Prices are low because the styling is plain. The three things that decide a good order are knowing whether an item is genuine surplus or a new reproduction, decoding military sizing, and getting boots to fit.

Genuine surplus versus reproduction

Army Navy Outdoors lists both. Genuine surplus is ex-issue kit, often described as new old stock, used or grade one. It is built to a military specification, so the fabric and stitching are tough, but sizes are limited to what was issued and the condition varies.

Reproductions from Rothco or Alpha copy the design in new fabric with a full size run and consistent colour. They cost less than surplus in some cases and more in others, depending on rarity.

The listing on Army Navy Outdoors will say which it is. If the description mentions a grade, a country of origin or the word used, it is surplus. If it lists fabric weight and a full size chart, it is a reproduction.

Buy surplus for wool blankets, ponchos and field jackets where the original spec matters. Buy reproduction when you need a specific size or a matching pair.

Military sizing explained

Field jackets, BDU shirts and trousers on Army Navy Outdoors use the military two-part size: a chest or waist band and a length. A jacket marked Medium Regular fits a medium chest and average height; Medium Long is the same chest for a taller wearer.

Trousers follow the same idea, with Small, Medium and Large covering a waist range and Short, Regular and Long covering inseam. The size charts on the product page give the exact inch ranges, and they are worth reading because a military Medium is roomier than a high-street Medium.

Surplus is cut for layering over a uniform, so it runs generous. If you plan to wear a field jacket over a jumper, take your normal size; over a tee, consider going down.

Boots

Army Navy Outdoors sells combat, jungle and tactical boots from makers such as Rocky, Belleville and Rothco. Leather and nylon combat boots need breaking in; a lighter tactical boot with a running-shoe sole does not.

Order the width as well as the length. Military boots often come in regular and wide fittings, and a wide foot in a regular boot is the commonest reason for a return.

Try boots on indoors with the socks you will actually wear before deciding to keep them. Boots worn outside are usually not returnable.

Cold-weather layers

The surplus layering systems Army Navy Outdoors stocks work as a set: a wicking base layer, a fleece or wool mid-layer, and a shell on top. Buying a shell one size larger than the mid-layer keeps the system moving.

Wool is the store's quiet strength. Surplus wool blankets, watch caps and glove liners are cheap, warm when damp and last for decades. Check the wool percentage; a 70% wool blanket is markedly warmer than a 50% one.

Camping and field gear

For camping, Army Navy Outdoors covers canteens and cups, mess kits, ponchos and poncho liners, sleeping bags, entrenching tools and packs. The GI-style poncho liner is one of the best-value pieces on the site: a light, quick-drying quilt that doubles as a summer sleeping bag.

Packs come in two families. ALICE packs are the older frame-and-bag design; they are cheap and huge but heavy. MOLLE-compatible packs use the modern webbing grid so pouches can be added. For a weekend hike, a mid-size MOLLE pack is easier to live with.

Sleeping bags are rated by temperature. Treat the stated rating as the survival limit, not the comfort limit, and buy a bag rated colder than the nights you expect.

Shipping, returns and surplus condition

Army Navy Outdoors ships from the US and has typically offered free shipping over a spend threshold. Boots and packs are bulky, so a single boot order may fall under the threshold while a boot-and-socks order clears it.

Returns generally require unworn items with tags. Used surplus is often sold as-is or with a limited return window, so read the condition description twice and ask the store before ordering if a grade is unclear.

Where the Army Navy Outdoors savings are

Work the break-even. A $20 code beats 20% on any Army Navy Outdoors basket under $100, which covers a jacket or a pair of trousers. Above $100, the percentage wins, so use it for boots, a pack or a full layering set.

The 15% code is the fallback if the 20% code has expired or is limited to a category. Codes on Army Navy Outdoors usually apply to full-price items only and may exclude some branded boots.

The store's own sales cluster around Memorial Day, Labor Day, Black Friday and the spring outdoor season. A percentage code on top of an already-reduced surplus lot is rare, so compare the sale price with the coded full price and take the lower.

Dollar codes often carry a minimum spend. Check the threshold before building a small order around one.

Common questions

How do I know if an Army Navy Outdoors item is real surplus?

The listing states a grade, condition or origin for surplus. Reproductions list fabric specs and a full size chart.

What does Medium Regular mean?

Medium chest or waist, average height. Long and Short change the length only.

Do military boots run true to size?

Length is usually true; width is the trap. Order wide if your feet are wide and try them indoors first.

Is a poncho liner worth buying?

Yes. It is a light, quick-drying quilt that works as a summer sleeping bag and packs small.