Abstract: A pad structure for a protective headgear comprising, a resilient foam inner pad, a thin flexible front cover sheet of a foam material being formed into a configuration defining a cavity of a shape to closely receive and cover inner and side surfaces of the inner pad. The pad structure has a back cover sheet of flexible material covering a back surface of the inner pad and joined to the front cover sheet along bond lines adjacent a back portion of the inner pad and extending around sides of the inner pad.