Custom Event T-Shirts: How to Order the Right Sizes
GET THE SIZES
RIGHT.
Every Time.
Custom event tees are simple — if you order smart. This guide gives you the Nevada-tested size formula, safety buffer rules, and real tools to nail your order from 24 shirts to 2,400.
The Gold Standard Method
Custom tees are the easiest way to make your event look sharp, build team spirit, and create memories that last. If you have a registration list — don't guess. A quick Google Form or RSVP text saves headaches and dead stock.
Whether it's a mining crew safety day in Elko, a family reunion in the high desert, an off-road club run out of Reno, or a corporate conference on the Las Vegas Strip — matching apparel says we're in this together. At Battle Born Clothing in Yerington, Nevada, we help crews, businesses, and families across the Silver State get their orders perfect every time.
Nevada-Proven Size Mix
For walk-ins or giveaways, use our field-tested breakdown. We've adjusted this slightly larger than national averages because a roomy shirt beats one that's too tight every single time.
| Size | Order % | Distribution | 50 Tees | 100 Tees | 200 Tees |
|---|---|---|---|---|---|
| Small | 12% | 6 | 12 | 24 | |
| Medium | 25% | 13 | 25 | 50 | |
| Large | 30% | 15 | 30 | 60 | |
| XL | 20% | 10 | 20 | 40 | |
| 2XL | 9% | 5 | 9 | 18 | |
| 3XL+ | 4% | 2 | 4 | 8 |
Know Your Crowd
Always Order 10–15% More
This covers last-minute sign-ups, on-site size swaps, and the inevitable volunteer who forgot to give you their size. The cost of 15 extra shirts is nothing compared to a frustrated guest.
We print on demand — if you order smart upfront, you can always come back for a small supplemental run. But running short at your event? That's not fixable on the day. Buffer early.
Battle Born Tough Fit Guide
We print on premium 100% ring-spun cotton blanks. Use these measurements to ensure your crew gets the right fit. See our full tee product page for detailed specs.
| Size | Chest (Inches) |
|---|---|
| XS | 32–34" |
| S | 35–37" |
| M | 38–40" |
| L | 41–43" |
| XL | 44–46" |
| 2XL | 47–49" |
| 3XL | 50–53" |
| 4XL | 54–57" |
Wrap the tape under the arms around the fullest part of the chest. When in doubt, size up — a slightly bigger shirt is always more comfortable than a tight one.
Local. Fast. Battle-Ready.
We aren't just a website — we're a real shop in Yerington, NV serving the entire state from Carson City to Elko to Las Vegas. Check out our laser engraving page for custom add-ons, or browse our blog for more gear guides.
Ready to Start?
Drop us your event details and we'll build a custom size recommendation for you — free, fast, no commitment.