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 the flex connectors which have plugs provided on the opposite ends of an intermediate cable section. The intermediate cable section includes multiple conductor wires having opposite ends projecting outwardly of an outer insulative cover or jacket. The plugs are attached to the opposite ends of the cable wherein each plug includes an outer housing and cover, as well as a plurality of multi-prong quad-point electrical terminals. Each terminal is connected to a respective wire and then fitted into an appropriate socket therefore.