Got it, thank you for your advice!
Read with interest so here’s my take
You’re right to be cautious here truck wraps are very much a “measure twice, cut once” situation. The safest starting point is always a proper template from the wrap company or a supplier, because no two box trucks are ever exactly alike. Even with flat panels, things like door seams, rivets, hinges, locks and handles can throw a design off if you don’t plan for them.
If a template isn’t available, get your client to provide exact make, model, year and body type, and then ask for photos from every angle. On top of that, have them measure all the panels and any hardware locations. A good trick is to mark up a photo with dimension lines so the client knows exactly what to measure.
In Illustrator, yes, you’ll usually set up a flat artboard for each panel. But don’t just design straight onto that. Create a hidden non-printing layer where you map out all the “nooks and crannies” door seams, handles, rivet lines, hinges etc. That way you have a permanent visual reference while you design, but it won’t interfere with the final print file. It also makes it much easier if the installer asks about placement later.
Always give generous bleed, 4–6 inches is typical on vehicle wraps, and avoid placing critical text or small details near edges, seams or moving parts. Wrap vinyl stretches and installers need wiggle room, so what looks precise on screen can shift in real life - especially designing at scale - if 1/10th the scale then half an inch out looks small but when scaled up is massive.
One more tip: over-communicate with the installer. They’ll know what tolerances they need and whether certain hardware should be wrapped, avoided or cut around. Think of it as a three-way collaboration between you, the client, and the wrap company. If you keep everything documented in that master template (with visible and hidden layers for guidance), you’ll be on much safer ground.
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Understood, thanks so much for your detail explanation. Really appreciate it!