A modular multi-component power distribution system is provided having a plurality of modular components which includes a bus-bar-like power distribution assembly (PDA), branching connectors, flex connectors, and receptacles. A manufacturing process relates to the manufacture of extruded power distribution assemblies and the insertion of multiple, lengths of conductor wire along the longitudinal length thereof. In such PDA's, multiple parallel bores are formed interiorly of the PDA casing or housing wherein such conductors are not inserted into the bores until after the PDA extrusions are cut to length and plug ports are formed therein.