How to Size Custom Rugby Jerseys for a Squad 2026

Learn how to size custom rugby jerseys for a full squad in 2026 — measure chest, waist and body length, apply position-based fit buffers, and order right first time.

July 08, 2026

Sizing a full squad for custom rugby jerseys is where most club orders go wrong — and a single missed measurement means a player hits match day in a jersey that bunches at the armpits or sits mid-thigh. This guide walks you through every step, from taking individual body measurements to submitting a clean size run to First Ever.

TL;DR: To size custom rugby jerseys for a full squad, measure each player's chest, waist, and body length, map those numbers against the supplier's size chart (not a generic chart), add a 2–3 cm fit buffer for contact-sport movement, and build a size spreadsheet before placing the order. Order at least 2 spares in your most common sizes. This process cuts reorder delays and keeps every player match-ready in 2026.

Why getting squad sizing right matters in 2026

Rugby jerseys are cut differently from basketball or soccer tops — heavier fabric, reinforced shoulders, and a closer collar sit mean that a player who wears a large in a training tee may need an XL in a custom rugby jersey. Australian club seasons typically kick off between March and April, so orders placed late January or early February need zero sizing errors to land on time. One wrong size run forces a reorder that can add 3–4 weeks to your timeline.

What you'll need

A flexible fabric tape measure (not a rigid builder's tape)
A spreadsheet with columns: player name, chest (cm), waist (cm), body length (cm), preferred fit (standard/relaxed), assigned size
The size chart from fecustom.com for the specific rugby jersey style you are ordering
15–20 minutes per 15-player squad to collect all measurements
A second person to hold the tape for chest measurements

Step 1: Measure each player individually

Action: take three measurements per player — chest, waist, and body length.

Generic sizing based on "he's usually a large" is the single biggest cause of fit complaints in squad orders. Chest measurement is the primary fit driver for rugby jerseys; waist and body length determine whether the hem stays tucked and whether the jersey restricts tackling posture.

Chest: tape around the widest part of the chest, arms relaxed at sides. Record to the nearest centimetre.
Waist: tape at the natural waistline, not the hips. This matters for shorter-cut performance fits.
Body length: measure from the highest point of the shoulder (next to the neck) straight down to where you want the hem to sit — typically mid-hip for rugby.

Collect all three numbers before you open the size chart. Common mistake: measuring chest over a thick hoodie and adding 4–5 cm of false bulk to the number.

Step 2: Map measurements to the supplier size chart

Action: use the size chart provided on the product page, not a generic Australian clothing chart.

Custom sportswear manufacturers cut to their own block, and that block can differ from retail sizing by one full size in either direction. Download or screenshot the size chart from the First Ever product page for the exact rugby jersey style you are ordering. If the size chart is not visible, request it before placing the order — this is non-negotiable.

Map each player's chest measurement first. If the chest falls between two sizes, size up. Rugby involves arm extension, tackling, and binding in scrums — a jersey that fits at rest will feel restrictive under load.

Expected outcome: every player in your spreadsheet now has a draft size assigned. Review the full list for obvious outliers before moving to the next step.

Step 3: Add a fit buffer for contact-sport movement

Action: add 2–3 cm to the chest measurement before finalising sizes for forwards; leave backs at the standard measurement.

Forwards — props, hookers, locks, flankers, number eights — spend time in scrums and mauls where jersey fabric is gripped, stretched, and pulled. A jersey cut to exact chest measurement will tear at the seams or restrict shoulder rotation within a season. Add 2–3 cm to a forward's chest number before mapping to the size chart.

Backs generally prefer a closer fit for aerodynamics and to make it harder for defenders to grab the jersey. Map backs at their actual chest measurement.

Common mistake: applying the same fit buffer to every position. A tighthead prop and a winger have completely different movement profiles.

Step 4: Build your size run spreadsheet

Action: tally the sizes and identify the most common two or three sizes in your squad.

A size run is the final count of how many jerseys you need in each size — for example, 2 × S, 4 × M, 5 × L, 3 × XL, 1 × 2XL. Build this before you order anything.

The spreadsheet should show:

Player name and position
Chest measurement (cm)
Assigned size
Fit preference (standard or relaxed)

Once tallied, identify which two sizes account for the most players. These are your "safety stock" sizes — the ones where you want spare jerseys in case a new player joins mid-season or a measurement was slightly off.

Step 5: Order 2 spare jerseys in your top sizes

Action: add 2 spare jerseys in the squad's two most common sizes to your order.

This is standard practice for any club ordering custom sportswear in 2026. Spares cost far less than a rush reorder. If your squad is 15 players and your two most common sizes are L and XL, order 2 × L and 2 × XL above the headcount. Label them as club property and store them in the gear bag.

Common mistake: ordering the exact headcount and leaving no room for a last-minute addition or a measurement error. A 15-player squad order with zero spares almost always results in at least one reorder before the season ends.

Step 6: Submit a clean order form

Action: send a finalised spreadsheet with player names, sizes, numbers, and any name/number customisation in one document.

Custom rugby jersey orders that arrive as a series of emails — "actually can you change Jake's to an XL" and "I forgot to add the captain's armband" — slow down production and increase error rates. Consolidate every player's details into a single spreadsheet row: name, size, jersey number, optional name on back.

Submit that one document with your order through fecustom.com. Production timelines for 2026 orders depend on completeness at submission — an incomplete brief is the leading cause of delays.

Check the current turnaround times on the site before you commit to a delivery date with your club.

Step 7: Confirm and review before production is locked

Action: read the order confirmation line by line and flag any discrepancy within 24 hours.

Once your order is confirmed, you typically have a short window — often 24–48 hours — to catch errors before production begins. Check every size, number, and name against your spreadsheet. This is the last point at which a change is cost-free.

Common mistake: skimming the confirmation and assuming it matches what was submitted. Size transpositions (an S entered where an XL was intended) are easy to introduce and easy to miss if you do not check line by line.

Troubleshooting

A player's jersey arrived too small even though you sized up. The most likely cause is measuring over bulky clothing. Re-measure on a thin training shirt and compare to the size chart. If the chest measurement is genuinely at the boundary between two sizes, go up one further for that position.

Two players have identical chest measurements but one finds the jersey restrictive. Body length and shoulder width affect perceived fit. A player with broader shoulders than average for their chest size will feel tightness across the upper back. Flag shoulder width as an additional measurement for any player who has flagged fit issues in previous orders.

The size chart on the product page doesn't match what arrived. Document the discrepancy with photos and measurements and contact First Ever directly. Custom sportswear manufacturers update fabric suppliers and cuts periodically; size charts should match the current production block.

A forward's jersey is tearing at the shoulder seam after 3 matches. This points to under-sizing, not a defect. Apply the 2–3 cm forward fit buffer and reorder that player's size up.

Youth and junior players are in between sizes. For junior players in 2026, always size up rather than down. Growth allowance and the physical demands of junior rugby both favour a slightly larger cut. Check whether the style you are ordering has a dedicated youth size run — some styles carry XS and S cuts that fit junior builds better than a downsized adult S.

A mid-season replacement player needs a jersey urgently. This is exactly what your 2 spare jerseys are for. If the spare doesn't fit, a single-unit reorder will be required — always check current lead times on the site before promising a turnaround.

Tools and resources

Flexible fabric tape measure — essential, not optional
Squad sizing spreadsheet (build in Google Sheets or Excel, columns as listed in Step 4)
fecustom.com size chart for your chosen rugby jersey style — download it before measuring anyone
Hurricanes mens rugby jersey — one of the rugby-specific styles available at First Ever with its own size chart
How to care for mens rugby jerseys after matches — once jerseys are delivered, this guide covers washing and maintenance to extend jersey life across a full season
Custom rugby jerseys for Australian club teams — context on ordering options for Australian clubs in 2026

FAQ

How do you size custom rugby jerseys for a full squad? Measure every player's chest, waist, and body length individually, map those measurements to the supplier's specific size chart, apply a 2–3 cm buffer for forwards, and build a size run spreadsheet before submitting the order.

What measurements do you need for a custom rugby jersey? Chest circumference is the primary measurement. Waist and body length are secondary but important for players at the boundary of two sizes or with a non-standard torso-to-hip ratio.

Should rugby jerseys be tight or loose? Backs typically prefer a closer fit; forwards need 2–3 cm of extra chest room to allow for the binding and contact work they do in scrums and mauls. A jersey that fits perfectly at rest will restrict movement under load.

How many spare jerseys should a club order? Order 2 spares in each of the squad's two most common sizes. For a 15-player squad, that means 4 additional jerseys — a small cost compared to a rush reorder mid-season.

Is a custom rugby jersey size the same as a regular clothing size? Not reliably. Sportswear manufacturers use their own size blocks, which can differ from retail clothing by a full size. Always use the specific size chart for the jersey style you are ordering, not a generic Australian sizing guide.

How long before the season should a club place its jersey order? For Australian club seasons starting in March or April 2026, aim to have your order submitted with a complete brief by late January. This accounts for production time and any minor corrections without risking late delivery.

What happens if a player's size is wrong after the jerseys arrive? Document the discrepancy with photos, compare to the original size chart, and contact the supplier. Going forward, always re-measure players who have flagged fit issues rather than repeating the previous order's size.

Can you order custom rugby jerseys in youth and adult sizes in the same order? Yes, provided the style has a youth size run. Confirm this on the product page before measuring your junior players — some styles only carry adult sizes, and a small adult S is not the same cut as a youth L.

One last thing

The most overlooked step in squad sizing is re-measuring players who ordered the previous season. Body composition changes — a player who was a true M in 2025 may be an L in 2026 after a preseason weights block. Treat every new season's order as a fresh measurement exercise, not a repeat of last year's size run. Five minutes of re-measuring saves a full reorder.

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