The purpose of this study was to examine selected physiological and psychological responses to strenuous live-fire drills in different configurations of protective firefighting gear. Career firefighters (n = 10) performed three sets of firefighting drills in a training structure that contained live fires in two different configurations of firefighting gear. On separate days subjects wore: (a) the NFPA 1500 (1987) standard configuration, and (b) a hip-boot configuration of the firefighting gear. Physiological and psychological measurements were recorded pre-activity and at the end of each trial. Repeated measures ANOVA revealed a strong trend for performance time to be greater in the 1500 gear than in the hip-boot gear. There was a significant Time x Gear interaction for tympanic membrane temperature, with temperature being greater in the 1500 gear. Perceptions of effort and thermal sensations were also greater in the 1500 gear than in the hip-boot configuration of the gear. There was little difference in mean performance on cognitive function measures between the two gear configurations, but there was greater variability in performance in the 1500 gear. These data suggest that performing strenuous firefighting drills in the current NFPA 1500 standard configuration results in longer performance time, greater thermal strain, and greater perception of effort and thermal sensation.