Abstract: Introduction: This study aimed to compare fit, musculoskeletal pain and interference issues experienced by male and female Australian soldiers when wearing body armour, as well as quantify the extent to which anthropometric characteristics contribute to these issues. Methods: 77 male and 12 female Australian soldiers completed a questionnaire about their perception of body armour, including questions about fit, musculoskeletal pain, interference with other equipment and mobility restrictions. Results: Females experienced disproportionate challenges with body armour fit, particularly excessive length and width, leading to greater musculoskeletal pain, equipment interference and mobility restrictions. Males also reported issues with body armour being too long and limiting mobility during occupational tasks. Front length was the strongest predictor of body armour-related issues, affecting mobility, comfort and acceptability more than chest breadth or circumference. Conclusion: Body armour size and design modifications, particularly to system length, are necessary to improve fit and occupational performance.