The United States Army's chemical protective battle dress overgarment (BDO) acts as an insulator resulting in heat stress to personnel when worn in a desert climate. The purpose of the study was to develop and test an alternative vapor adsorption liner. The BDO liner consists of a polyurethane foam impregnated with 120 g/m² activated carbon powder mixed in a slurry of latex with a 47.4 g/m² (2 oz/yd²) nylon tricot knit flame bonded to one side. A 120 g/m² activated carbon-nonwoven was developed and challenged with 1700 ppm trichloroethylene vapor. The activated carbon-nonwoven exhibited a higher vapor adsorption capacity to the Army's BDO liner but failed the Army's air permeability and bursting strength requirements. A continuous lightweight and thin membrane impervious to hazardous vapors but allowing perspiration vapor to penetration should be investigated as an alternative to the BDO liner.