How to Measure and Order Custom Hydraulic Hoses (Without Guesswork)

Properly bundled hydraulic hoses minimize abrasion and ensure organized routing — a critical part of any custom hydraulic solution.

When it comes to keeping your hydraulic systems running efficiently, off-the-shelf hoses don’t always cut it. Whether you’re dealing with tight tolerances, unusual routing paths, or demanding environmental conditions, custom hydraulic hoses are the clear choice.

But ordering the right custom hose isn’t just about sending measurements scribbled on a napkin. It’s about understanding your system, matching specs precisely, and working with a provider who gets it right the first time.

Let’s break down how to measure, spec, and order a custom hydraulic hose that fits your needs — and avoids downtime disasters.

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Why Go Custom Instead of Off-the-Shelf?

Standard hoses are built for generic use. But your machinery isn’t generic.

Custom hydraulic hoses:

• Fit exactly into your equipment’s routing paths

• Are built to match specific pressure ratings and temperature ranges

• Support custom end fittings, thread types, and lengths

• Prevent performance loss due to crimp failures, misalignments, or excess slack

In short? They perform better, last longer, and make maintenance a whole lot easier.

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Step 1: How to Measure for a Custom Hydraulic Hose

When ordering a custom hose, precision is everything. Here's what you need to measure:

A. Hose Length

• Measure from fitting end to fitting end (including the threads if you're using angled fittings)

• For routing with bends, account for curve radius — don’t measure in a straight line

B. Hose ID (Inner Diameter)

• Match the ID to fluid flow requirements

• Undersized hoses create pressure drops and heat — oversized can waste space and increase cost

C. Hose Fittings

• Identify fitting type: JIC, NPT, BSP, ORFS, SAE, etc.

• Note thread direction and angle (straight, 45°, 90°)

• If unsure, send a photo or sample to PSI — we reverse-engineer fittings in-house

D. Operating Environment

• Will the hose be exposed to UV, chemicals, abrasion, or extreme temps?

• Specify if you need protective sleeving, spiral wrap, or stainless steel fittings

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Custom hose assemblies ensure proper angles, pressure handling, and performance for high-demand hydraulic systems like this construction cylinder.

Step 2: Matching Hose Specs to System Needs

Every hydraulic system operates differently. A perfect custom hose balances:

• Flow rate (dictates ID)

• Operating pressure and surge pressure

• Fluid type compatibility

• Flexibility requirements (tight bends = higher bend radius rating)

• Safety factor (usually 4x operating pressure)

  
  

  Tip: Never guess pressure ratings. When in doubt, go one grade higher.

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Step 3: What to Include in Your Order

When sending an order or quote request to a supplier like PSI Hydraulics, include:

• Hose type and material

• ID and length (in inches or mm)

• Fitting type and angle (both ends)

• Pressure rating or system operating pressure

• Environmental considerations

• Quantity needed

• Application (optional, but helpful)

Still unsure? PSI offers free consultations — just send a photo, and we’ll walk you through it.

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Common Mistakes (and How to Avoid Them)

Let’s be real — a lot can go wrong with hoses. Here are the top issues we see, and how you can sidestep them:

Wrong fitting type: Leads to leaks or total incompatibility

Solution: Use calipers or send in a sample for exact match

Over-tight bends: Causes hose fatigue and rupture

Solution: Use the correct bend radius — PSI helps calculate it

Misjudging pressure requirements: Can cause failure under load

Solution: Specify both operating and max surge pressures

Ordering by “feel”

Solution: Get it measured or mocked up — PSI can help both remotely and on-site

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Pro Tips for Ordering Custom Hydraulic Hoses

• Bundle your order with other parts (fittings, sleeves, brackets) to avoid delays

• Ask for test certification if your system is mission-critical

• For field repairs, consider hose kits with spare fittings included

• Label hoses in the field to make reordering easier later

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Why PSI Hydraulics Is the Right Partner

At PSI Hydraulics, we don’t just build hoses — we engineer custom-fit hydraulic solutions that meet real-world demands.

• In-house crimping and pressure testing

• Decades of hydraulic experience across oil & gas, construction, and manufacturing

• Fast turnaround — even same-day for emergencies

• Precision from spec to final fitting

We’ve seen what happens when hoses fail. That’s why we build them to last.

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Before placing an order, technicians often inspect worn or mismatched hoses in the field — custom replacements ensure a perfect fit every time.

Ready to Order a Custom Hose?

Whether you know your specs or need help figuring them out, we’ve got your back. Our team is standing by to build exactly what you need — with no guesswork, no wasted time, and no compromises.

Contact us to receive a custom quote today.