Totally agree here. Just like a hat a body protector should be replaced when it's been in an accident. If new then yes the inner foam can bounce back, but always check the stitching and the threads as these are what can break and not protect you incase of another accident! i know they can be...
I recommend the shires sweetitch rug, I aswell was sick to death of the fly rugs splitting and breaking every 5 mins! had several amigo ones i tried to rotate last year that were definatley not coming into this summer alive!
also find this rug is good against the wet weather! (not waterpoof but...
totally agree with this! each brand is completely different for me! but me a size 8-10 have found size 28" jods to be more comfortable! it's a case of trying on i think :D
Have you got a snack ball that he can play with and put some pony nuts in? (Presuming this won't put to much pressure on his leg)
or a string with his favorite veg on that you can hang somewhere (presuming you hang the hay net so there could be somewhere to hang in the field if he is not...