A team jersey can look spot-on in the design proof and still become the one everyone leaves at the back of the drawer if the fit is wrong. Knowing how to size custom team jerseys properly helps your group avoid tight sleeves, flapping bodies, overstuffed pockets and the awkward situation where half the team needs an exchange after the first ride.
For cycling clubs, workplace groups and event teams, sizing is not just about matching a chest measurement to a chart. Riders have different builds, fit preferences and expectations. A good process gives everyone a clear way to choose, while keeping the final order manageable for the organiser.
Start with the intended riding fit
Before anyone reaches for a tape measure, agree on the type of fit the team wants. This is where many custom orders go off course. Someone who expects a relaxed club jersey may find a race-cut jersey restrictive, even when their body measurement technically matches the chart.
A performance cycling jersey is designed to sit close to the body. That reduces fabric movement in the wind, keeps pockets more stable when loaded and helps moisture move away from the skin. It should feel fitted when standing, but more natural once you are leaning forward on the bike.
A more relaxed cut gives extra room through the torso and arms. It can suit newer riders, commuters, casual group rides or teams with a broad mix of body shapes. The trade-off is that loose fabric can bunch at the front or catch the wind at speed.
For most regular group riders covering 30 to 80 km, a comfortable performance fit is a sensible middle ground. Close enough to work on the bike, without feeling like you need to hold your breath at the kopi stop.
Fit preference matters as much as measurements
Two riders with the same chest size may genuinely need different jersey sizes. One may prefer a close, aerodynamic feel, while another may want more room around the stomach or shoulders. Neither choice is wrong.
Ask each rider to consider how they wear their existing cycling jerseys. If their favourite jersey is fitted but comfortable, use it as the main reference. If they regularly size up because they dislike compression around the arms or waist, that preference should be recorded rather than corrected.
The goal is not to make every rider choose the smallest possible size. The goal is a jersey they will wear for long rides in heat and humidity, not only for a team photo.
How to size custom team jerseys using a size chart
Use the size chart for the exact jersey model being ordered. Do not assume that a medium in a cotton T-shirt, running top or another cycling brand will translate directly. Cycling jerseys are built with different fabrics, stretch levels and pattern shapes.
The most useful measurements are usually chest, waist and hip. Measure against bare skin or a thin base layer, keeping the tape level and comfortably firm rather than pulling it tight. Record the largest relevant measurement, especially if a rider sits across two size ranges.
For the chest, measure around the fullest part of the chest with arms relaxed. For the waist, measure around the natural waist or the point stated on the chart. For the hip, measure around the fullest part of the hips and seat. This matters because a cycling jersey needs to stay comfortable when its rear pockets carry a mobile phone, tools and snacks.
If a rider falls between sizes, use fit preference and body shape to decide. A rider with broader shoulders, a fuller chest or a larger waist may be happier sizing up. A lean rider who wants a close fit may prefer the smaller option, provided the jersey does not pull across the shoulders or strain at the zip.
Height and weight can help as a secondary check, but they should not make the final decision. Two people of the same height and weight can have very different proportions.
Measure an existing jersey for a useful comparison
An existing jersey that fits well is often the simplest reference point. Lay it flat on a table without stretching it, zip it up and measure the chest width from armpit to armpit. Then compare that measurement with the garment measurements provided for the custom jersey.
This method is particularly helpful for riders who know what feels good but are unsure how to take body measurements. Just make sure you are comparing like with like. A relaxed jersey measured against a race-cut jersey will not tell the full story.
Also check sleeve length, front length and rear length if these are available. Riders with longer torsos may appreciate extra coverage at the back, while those who prefer a shorter, cleaner fit may not.
Test the fit in a riding position
A jersey can feel slightly unusual when you are standing upright because cycling clothing is patterned for a forward-leaning position. That is normal. The better test is to mimic your riding posture, with hands forward and shoulders relaxed.
In that position, the zip should lie flat without pulling open. The collar should sit comfortably rather than pressing into the throat. The shoulders should not feel tight when reaching for the bars, and the sleeves should stay in place without digging into the upper arm.
At the waist, the gripper should hold the jersey down without rolling upwards. If the front rides up or the back feels too short when bending forward, the jersey may be too small or the cut may not suit that rider’s shape. Rear pockets should sit flat when empty and remain stable with a few ride essentials inside.
For hot, humid riding conditions, avoid choosing an oversized jersey simply to feel cooler. Loose fabric does not always improve comfort. A jersey with breathable fabric and a well-fitting shape can manage sweat more effectively, while excess material may hold moisture and flap in the wind.
Give the team a simple sizing process
The organiser should not have to become a full-time tailor. A clear process reduces confusion and gives riders ownership of their choice.
First, share the exact size chart and explain whether the jersey is performance fit or relaxed fit. Next, ask riders to measure themselves or compare a favourite jersey at home. Set a firm cut-off date, then collect each person’s chosen size alongside their preferred name and number, if applicable.
It helps to include a short note: if you are between sizes, choose based on your preferred fit and your largest measurement. Riders who prefer more room should generally size up. This is more useful than telling everyone to choose their usual T-shirt size.
If the group is large, keep a simple record of each rider’s chest, waist, chosen size and fit note. A note such as “between M and L, prefers relaxed fit” can prevent a last-minute debate when the order is submitted.
Use sample sizing when the order is significant
Where possible, try on sample jerseys in the same cut before confirming the full order. This is the most reliable route for a new team, a large club order or a group choosing a more fitted performance design.
A sample session does not need to be formal. Bring a size run to a weekend ride, let riders try jerseys over a base layer and ask them to bend forward as if they are on the bike. A few minutes of honest feedback can save weeks of frustration later.
If samples are not available, use the measurement chart carefully and encourage riders not to guess. Custom jerseys are made for the team, so changes after production are often more limited than with standard retail stock.
Plan for different riders, not one “average” rider
A good team kit should make the whole group feel included. That means offering the full available size range and avoiding pressure for every rider to fit a particular look.
Some riders will want a close-cut jersey for faster weekend efforts. Others may be returning to cycling, carrying more around the midsection or simply prefer breathing room. Women’s-specific cuts, where available, can also provide a better fit through the shoulders, chest and waist than a unisex jersey sized down.
Do not overlook sleeve and torso preferences either. Tall riders may need length more than width, while compact riders can find a larger size too long even if it fits around the chest. This is where trying a sample or reviewing garment measurements becomes valuable.
At Bizkut, custom team apparel is built around real riding comfort, not the idea that one shape should suit everyone. A team kit works best when people are happy to wear it for the hard kilometres as well as the café photo.
Check the final size list before production
Before approving the order, send the final size list back to the team. Ask riders to confirm their own entry, including any personalisation. This last check catches surprisingly common mistakes: a size selected by a friend, a typo in a surname, or a rider who changed their mind after realising the cut is fitted.
Make it clear that the final confirmation is the point to speak up. Once custom production begins, adjustments are not always possible. That is not about being strict for the sake of it. It is simply how made-to-order apparel works.
The best-sized custom team jersey is the one a rider forgets about after the first few kilometres. It stays put, breathes well, carries what it needs to carry and lets the group focus on the ride ahead.