Protective element for sports pads and the like

A method of manufacturing a leg pad core, comprising:

• forming foot and leg sections with a stiffener layer of impact resistant material retaining a first curved configuration at ambient temperature and returning to the first curved configuration after deformation;
• connecting a layer of flexible material to a first surface of the stiffener layer;
• heating the core to heat the stiffener layer to a formable state;
• deforming the heated core to create a second curved configuration for the stiffener layer different from the first curved configuration;
• cooling the core to ambient temperature to set the second curved configuration, the stiffener layer returning to the second curved configuration after deformation following setting of the second curved configuration.

A method of adjusting a leg pad including a core with foot and leg sections defined by a stiffener layer of impact resistant material retaining a first curved configuration at ambient temperature and returning to the first curved configuration after deformation, and a layer of flexible material conforming to a surface of the stiffener layer, the method comprising:

• heating the leg pad to heat the stiffener layer to a formable state;
• deforming the heated pad to create a second curved configuration for the stiffener layer different from the first curved configuration;
• and
• cooling the pad to ambient temperature to set the second curved configuration, the stiffener layer returning to the set-second curved configuration after deformation following setting of the second curved configuration.