The present invention is a system and method for custom tailoring and manufacturing apparel by using numerous try-on apparels (10) of differing, predetermined dimensions to make a finished product. A system (40) is used to keep track of the number of try-on apparels (10) and each of their dimensions. As a consumer tries on one of these try-on apparels (10), a device (40b, 40c) associated with the system (40) is used to collect the consumer's responses about fit. If one try-on apparel (10) does not fit, the system (40) suggests a next one to try, according to pre-defined rules. When a particular try-on apparel's fit has been approved for purchase by the consumer, this is reported to a manufacturing system (70), where a piece of apparel corresponding to the dimensions of the approved try-on apparel is cut, stitched, treated, and shipped as a finished apparel.