Sizing a full squad in custom soccer jerseys is a different job than sizing one shirt for yourself β get it wrong across 18 players and you're paying for reprints out of your own pocket.
- Measure chest circumference first, not height or age β it decides fit more than any other number.
- A 2026 soccer jersey sizing guide for a full squad needs a size run, not a single size guessed for everyone.
- FE Custom's youth and mens ranges use different block patterns, so never size a 14-year-old off an adult chart.
- Collect measurements with a printable chart and a fabric tape, not guesswork from last season's kit.
- Order 1-2 spares in the two most common sizes β buy this, skip ordering one size for the whole squad.
Why this matters
A squad kit order isn't one transaction β it's 15 to 25 separate sizing decisions bundled into one invoice. Miss the mark on a handful of players and you're either paying for reprints, sending a bulky size 3XL to a 10-year-old, or watching a striker play in a jersey that pulls across the shoulders every time they raise their arms.
Custom soccer jerseys are printed to order in 2026, which means there's no shelf stock to swap from once the run is cut. Getting the sizing guide right before you submit the order is the only real quality control step a club committee has.
What you'll need
- A fabric tape measure (not a rigid ruler β chest and waist need to wrap)
- A soccer jersey fit reference to match body measurements against actual garment sizing, not just age brackets
- A spreadsheet or printed roster sheet with one row per player
- 20-30 minutes for a squad of 16-20 players (measuring takes longer than ordering)
- Separate size charts for mens, womens and youth cuts β never cross-reference between them
- A decision on reversible vs. printed jerseys, since reversible V-neck styles run slightly closer through the torso
The steps
1. Measure chest circumference on every player
Chest, not height, drives jersey sizing. Run the tape under the arms, across the fullest part of the chest, and record it in centimetres. This single number gets you 80% of the way to the right size before you even look at a chart.
Common mistake: measuring over a hoodie or thick training top adds 3-5cm and pushes players into a size too big.
2. Split the squad into mens, womens and youth categories before sizing
Don't size a 15-year-old goalkeeper off the mens chart just because they're tall. Youth block patterns are cut narrower through the shoulder and shorter in the body, and mixing charts is the single most common squad-order error clubs make.
If your squad has mixed age groups, sort the roster into three groups first and size each group against its own chart.
3. Cross-reference chest measurement against the actual size chart, not memory
Every jersey range has its own chart β a size Medium in one cut can differ by 2-3cm from a Medium in another. Pull up the product page for the exact jersey style you're ordering and match centimetres to size letter, every time.
Expected outcome: a size letter (S, M, L, XL, etc.) assigned to every player, not a guess based on what they wore last year.
4. Add growth allowance for youth squads ordering mid-season
For junior clubs ordering in the first half of the 2026 season for a kit that needs to last through finals, size up one increment for players who are still growing fast β typically under-14s. A jersey that's slightly loose in March still fits in September; one that's tight in March won't.
Common mistake: sizing junior players exactly to their current measurement and then facing a mid-season reprint request.
5. Build the size run before submitting the order
Once every player has a size letter, tally them into a size run: for example, 3x Small, 8x Medium, 6x Large, 2x XL. This is the number that goes on the order form β not a single size multiplied by squad count.
A size run also flags outliers fast. If your run shows 1x XXXL sitting alone against a squad of Mediums and Larges, double check that measurement before you submit.
6. Confirm goalkeeper and outfield sizing separately
Goalkeepers often wear a looser fit for padding and movement underneath, so don't default them to the same size as an outfield player with an identical chest measurement. Flag goalkeeper kit as its own line in the size run.
7. Lock the roster sheet and cross-check names against numbers
Before submitting, cross-check every player's name-and-number pairing against their assigned size. This is the step teams skip when they're rushing a deadline, and it's the one that causes the most support tickets after delivery.
For a squad ordering FE Custom jerseys for the first time, a men's run like the Club Athletica raglan soccer jersey (25 items) is built as a ready-made bulk quantity, which makes the size-run maths above easier to slot straight into an order of that volume. For junior sides, the Royals youth reversible V-neck jersey (12 items) uses the narrower youth block pattern from step 2, so measuring against its own chart matters more than usual.
Troubleshooting
- Sleeve length looks wrong even though chest fits. Chest circumference is the sizing decision; sleeve and body length are a secondary tailoring detail on most cuts and vary slightly by style, so check the specific product's measurements rather than resizing off chest alone.
- Two players with the same chest measurement need different sizes. This usually means one runs longer through the torso. Size to chest first and treat the length difference as a fit preference, not a sizing error.
- A player's measurement sits exactly between two sizes. Round up for outfield players who want freedom of movement, round down for a snugger match-day fit β there's no universal rule here, so ask the player's preference.
- The hem sits too high or too low after delivery. This comes back to hem circumference, not chest β check the hem circumference measurement guide before assuming the whole jersey is the wrong size.
- Youth players outgrow jerseys mid-season. Build growth allowance into the initial order per step 4 rather than reordering individual replacements later β reprints of a single jersey rarely match dye lots exactly.
- The size run submitted doesn't match the final invoice count. Recount the roster sheet against the size run before checkout; this mismatch is the most common reason orders get held up for clarification.
Tools and resources
- Fabric tape measure and a printed roster sheet, one row per player
- The jersey style's own size chart, pulled from its product page β never a generic chart
- A locked-down roster spreadsheet as the single source of truth for the club committee
What to do next
Once sizing is locked, the next decision is how the order itself gets structured β design proofing, deadlines and payment terms all sit downstream of the size run you've just built for your 2026 season.
FAQ
What's the best way to size custom soccer jerseys for a full squad?
Measure chest circumference for every player, split the roster into mens, womens and youth groups, then build a size run before ordering. This avoids the single-size-for-everyone mistake that causes most squad reprints.
Is chest measurement more accurate than height for jersey sizing?
Yes, chest circumference predicts jersey fit far better than height or age. Height varies within a size range while chest is the number the actual garment block is cut to.
How do I size youth soccer jerseys that need to last a full season?
Size up one increment for players still growing fast, typically under-14s. A jersey that's slightly loose in March still fits by September finals.
Can I use the mens size chart for teenage players?
No. Youth block patterns are cut narrower in the shoulder and shorter in the body, so always size teenagers against the youth chart even if they're tall.
What is a size run and why do I need one?
A size run is the tally of how many jerseys you need in each size, such as 3x Small, 8x Medium, 6x Large. It's what goes on a squad order form, not a single size multiplied by headcount.
Should goalkeepers get a different size to outfield players?
Often yes, because keepers prefer a looser fit for padding and movement. Flag goalkeeper kit as its own line in the size run rather than defaulting to their chest measurement.
How much does a custom soccer jersey cost in Australia in 2026?
Pricing depends on style and quantity, so check the current price on each product page. Bulk squad runs are priced per set rather than per single jersey.
One last thing
The fastest way to blow a squad order isn't a bad measurement β it's sizing a mixed-age squad off one chart because "they're all teenagers." Under-14s and under-17s sit on genuinely different block patterns, and treating them as one group is the single biggest cause of mid-season reprint requests.
βIf two players share the same chest measurement but play different age groups, size to the age-group chart first β chest alone won't save you from a mixed-pattern order.β