Black Stallion BSX Welding Cap Review: The FR Cotton Cap That Earns Its Keep
There is a moment on a full production day when a stray spark finds the gap between your helmet and the cap underneath, and you feel it land. If you are wearing standard cotton, it stings and leaves a small burn mark. If you are wearing FR cotton, the spark lands, chars a thread or two, and goes out. Over a thousand hours of arc time, that difference adds up in ways that matter.
The Black Stallion BSX AH1631-NB is built on that logic. It is an FR cotton welding cap with a silicone grip interior band, a hidden bill extension for extra neck protection, and enough refinement in the construction to make it feel less like PPE and more like a cap you want to wear. That is harder to pull off than it sounds.
A welding cap is the last line of defense between your scalp and the heat environment inside a helmet. The helmet shell does most of the work, but sparks and UV radiation find their way around it on overhead passes, at odd angles, and on joints that require you to hold a position for a long time. The cap needs to be there when that happens. Standard cotton is adequate for hobby welding. For production work, overhead welding, or pipeline applications, FR cotton is the professional choice.
The Black Stallion BSX AH1631-NB is that cap.
What Makes the BSX Cap Different
The AH1631-NB is built from 7oz flame-resistant cotton. At 7oz, it is lighter than BOCOMAL’s 10oz canvas duck while still delivering genuine FR protection. The lighter weight means better breathability in hot shops and less bulk under a helmet, which reduces the fatigue that comes from wearing a tight-fitting helmet for hours.
The silicone grip band on the interior is a practical feature that gets overlooked in most cap discussions. When you tilt your head at steep angles for overhead work, a standard cap slides forward and ends up pressing against the front of your helmet at the wrong spot. The silicone grip keeps the cap in position so it sits where you put it. After a few hours of positional welding, you notice.
The hidden flap inside the bill is the other distinctive feature. The bill folds out to extend neck coverage, protecting the back of the neck and the upper ears from sparks and UV on overhead passes. This is not something you find on Comeaux, YESWELDER, or BOCOMAL caps. On production overhead work, it makes a real difference.
The cap is machine washable with FR protection rated for up to 50 home washes. After 50 washes, the FR protection begins to degrade. This is standard for chemically treated FR cotton (as opposed to inherently FR fibers like Nomex). Keep track of your wash count if you are relying on this cap for certified protection.
FR Cotton vs. Standard Cotton: The Meaningful Upgrade
Most welding caps sold at entry-level positioning use standard cotton or Martin fabric. Neither is certified to NFPA 2112 or rated with an ATPV. They resist brief spark contact adequately but will ignite and sustain flame if exposed to a sustained arc or larger spatter event.
FR cotton is different in two important ways. First, it self-extinguishes when the heat source is removed, rather than continuing to burn. Second, it can carry a documented arc rating (ATPV in cal/cm2) that tells you the energy level at which the fabric begins to fail. The BSX AH1631 uses FR cotton that addresses both.
For welders who work in environments with arc flash exposure requirements, FR PPE is not optional. For welders who work in production shops with sustained overhead or positional welding, FR cotton is the professional standard. The BSX makes it accessible without requiring a large purchase.
Compared to BOCOMAL’s HRC2 canvas duck, the BSX is lighter (7oz vs. 10oz) and adds the silicone grip and hidden bill extension. The BOCOMAL carries a higher cal/cm2 rating because of the heavier canvas weight. For most welding applications, the BSX’s 7oz FR cotton is more than sufficient and significantly more comfortable on a long shift.
Named flaw: The BSX AH1631 is not reversible. It comes in a solid navy and black colorway with no flip option. If you want the personality of a patterned or reversible cap, this is not it. The available sizes also run in Small, Medium, and Large rather than precise half-size increments, which means some welders land between sizes. The Medium fits most, but welders at the upper edge of Medium will find the cap slightly tight after extended helmet wear. Size up if you are not sure.
Does the BSX Come in Reversible Styles?
No. The AH1631-NB is a solid-color cap. Black Stallion does not offer a reversible version of the AH1631 line. If reversibility is important to you, Comeaux Caps is the better choice, with the understanding that you are trading down from FR cotton to standard cotton.
For welders who need FR protection, the trade-off is clear: take the BSX without the reversible feature rather than buying a reversible cap without the FR rating. The FR protection is the meaningful variable on a real welding job.
Comparison Table
| Feature | Black Stallion BSX AH1631 | BOCOMAL HRC2 (B0993B46LH) | Comeaux Reversible |
|---|---|---|---|
| Material | 7oz FR Cotton | 10oz FR Cotton Canvas Duck | 100% Cotton (standard) |
| FR Certified | Yes | Yes | No |
| Silicone Grip | Yes | No | No |
| Hidden Bill Extension | Yes | No | No |
| Reversible | No | No | Yes |
| Wash FR Durability | 50 washes | Inherent FR | N/A |
| Sizes | S / M / L | 6-7/8 to 8 | Half sizes |
FAQ
Is the Black Stallion BSX cap flame resistant? Yes. The AH1631-NB is made from 7oz FR cotton and is machine washable with FR protection rated for up to 50 home washes. It is a certified FR cotton garment, not a standard cotton or treated-blend cap.
How does the BSX compare to Comeaux Caps? Comeaux Caps uses standard 100% cotton with no FR rating. The Black Stallion BSX uses FR cotton with documented protection and adds a silicone grip band and hidden bill extension. For any welding with real arc exposure, the BSX is the more protective choice. Comeaux wins on print variety and reversibility for light-duty use.
Does the Black Stallion BSX come in reversible styles? No. The AH1631-NB is a solid-color cap in navy and black. There is no reversible version in the AH1631 line.
How long does the FR protection last on a Black Stallion BSX cap? FR protection is rated for up to 50 home washes. This is standard for chemically treated FR cotton. After 50 washes, the protective treatment begins to degrade. If you are relying on the FR rating for safety-critical applications, replace the cap at the wash limit.
What sizes does the Black Stallion BSX AH1631 come in? The cap comes in Small, Medium, and Large. It does not use the traditional hat-size numbering system. Medium fits most standard head sizes. Size up if you fall at the upper edge of a Medium.
Can the Black Stallion BSX be worn outside of welding? Yes. The FR cotton construction and low-profile fit make it suitable for any application where scalp protection from heat and sparks is needed: electrical work, grinding, or other industrial tasks where FR PPE is appropriate.
What is a silicone grip band on a welding cap? A silicone grip band is a strip of silicone material sewn into the interior headband of the cap. It creates friction against the scalp to keep the cap from sliding when you tilt your head at steep angles during overhead or positional welding.
Is Black Stallion BSX a reputable brand? Black Stallion is a brand under Revco Industries, a US-based welding PPE manufacturer. They have been producing FR welding gear for decades. The BSX line is their mid-range offering designed for professional production welders.
References
- Black Stallion BSX official product page: AH1631 FR Cotton Welding Cap (blackstallion.com)
- NFPA 2112: Standard on Flame-Resistant Clothing for Industrial Personnel
- OSHA: Welding, Cutting, and Brazing - Personal Protective Equipment
- American Welding Society: Safety and Health
- Revco Industries / Black Stallion: FR Cotton information (blackstallion.com)
