Ordering the wrong sizes is the most common and most expensive mistake in team kit orders. Too many mediums, not enough youth sizes, a few players who cannot wear their kit at all. This guide shows clubs, schools and academies in the USA, the UK, Ireland, Europe, Australia and New Zealand how to get the size mix right the first time.
Step 1: Collect sizes per player, not per team
Never guess a size curve. Send every player or parent a short form with:
- player name and preferred number
- size for each item (jersey, shorts, jacket)
- height for junior players, in case they are between sizes
A shared spreadsheet or online form works well. Set a deadline and chase late replies early.
Step 2: Use a size set, not a size chart alone
Size charts help, but nothing beats trying the real garment. Order a set of samples in the key sizes and bring them to training. Players try them on and confirm their size. This avoids most exchanges. Cuts differ between brands, so a “medium” from your old supplier may not match a new one.
Step 3: Plan for juniors who are growing
- Many clubs order one size up for younger juniors at the start of the season.
- Check the age-to-size guide and use height as the tie-breaker.
- Keep a few spare pieces in the most common junior sizes for players who join later.
Step 4: Think about fit by sport
| Sport | Fit to consider |
|---|---|
| Rugby, GAA, AFL | Close fit, so the jersey is harder to grab |
| Ice hockey | Roomy cut over pads; goalie cut is wider |
| Netball | Dress, bodysuit or skort, each sized differently |
| Cycling | Close fit; race fit runs smaller than club fit |
| Basketball and volleyball | Loose basketball fit vs close volleyball fit |
See our size charts and read netball dress vs bodysuit vs skort.
Step 5: Check the minimum order
Most factories set a minimum per design. With Pexton Apparel it is 30 pieces per design, and sizes from youth to adult can be mixed within it. So a squad of 18 seniors and 12 juniors in the same design can be one order. Read how mixing sizes works.
Step 6: Send one clean list
Send the factory a single spreadsheet with name, number and size per item for every player. Ask for each player’s kit to be packed and labelled separately. This is how we make and check every order at Pexton Apparel.
Step 7: Order spares
A few spare jerseys in common sizes cover new players, injuries and lost kit, and they come from the same production run, so colours match.
Quick checklist
- Collect sizes per player with a form.
- Try on a size set at training.
- Size up for growing juniors.
- Choose the right cut for the sport.
- Send one clean list with names and numbers.
- Add a few spares.
Ready to order? See our teamwear for clubs and academies, the club kit ordering timeline or send your size list for a free quote.