There are three reasons why you'll surface a rib injury :
o An ill fitting seat. You need to ensure that there's minimal lateral movement when you're sitting in the kart as this will be exacerbated when you're cornering.
o Falling out of the seat. Even if the seat fits well, you will get thrown from the seat when yumping kerbs and/or if the kart starts 'bouncing' through fast corner.
o Protrusions in the seat. Irrespective of how well you fit the seat, these will repeatedly hit the same part of your body as it moves and will cause muscle or rib damage.
Aside from ensuring you don't have protrusions against your ribs when seated in the kart, the additional solutions I'd advise are :
1. The Tillet Ribcage. This consists of two flexible wings that actually hold you in the seat and prevent you from sliding forward and falling out. This alone will significantly reduce the chance of rib injury.
http://www.tillett.co.uk/racing-accessories.asp
2. OMP carbon rib protector. This is a carbon-based waistcoat that will envelope your rib cage and reduce the chance of damage in the event you do move about in the seat.
http://www.demon-tweeks.co.uk/products/ProductDetail.asp?cls=MSPORT&pcode=OMPKK047L
Both will provide additional protection in some types of crash, but not all. However they're primary use would be to protect you from rib injury during normal track driving and some bumping/boring that happens during racing.
Having recently broken my ribs while wearing an inferior foam based waistcoat, I can vouch for the two items above. If I had those in place I wouldn't have been injured.
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