Custom Ignition Lead Set Boxes
Custom ignition lead set boxes from 100 — long cartons for spark plug wire sets of four, six and eight leads plus the coil lead, laid in cylinder order so an installer can fit them one by one, with a window on the performance lines and fitment where a counter looks for it.
Leads in order, not in a tangle
- Board
- 18–24 pt SBS boxboard; E flute for long heavy sets
- Inside
- Channeled board tray in length order, numbered to the leads
- Styles
- Long flat carton, tall window carton, hang-tab carton
Get a price for Ignition Leads Set Boxes
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
Laid flat, in length order
Each lead lies in its own channel of a board tray, longest to shortest, with the boots at one end. The tray numbers each channel to match the numbered sleeves or tags on the leads. Leads are laid in gentle curves rather than folded, because a sharp fold in a silicone lead can damage the conductor inside.
Carton shapes
| Long flat carton | The common set box; leads laid full length on a tray |
|---|---|
| Tall display carton | Leads looped in an upright tray behind a window |
| Hang-tab carton | For peg display in retail aisles |
| Header bag and card | Economy sets; less protection for the boots |
The window and the color
- Performance leads are sold on color and diameter — show them through a window.
- Keep the window clear of the part number and fitment panel.
- A clear film window keeps dust off the boots.
- Print the lead diameter large; it is one of the first things compared.
Fitment and part number
The part number goes on the front and both ends, with engine and vehicle fitment on the back or a side. Sets for one engine family often share a carton, so the fitment panel is printed as a variable area. For the plugs that go at the other end of these leads, see our spark plug boxes for singles and sets.
Ignition Leads Set Boxes — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Board
- 18–24 pt SBS boxboard; E flute for long heavy sets
- Inside
- Channeled board tray in length order, numbered to the leads
- Styles
- Long flat carton, tall window carton, hang-tab carton
- Window
- Clear film window on performance lines
- Panels
- Part number front and ends, fitment, lead diameter
- Full color; foil on premium sets
- Minimum
- 100 boxes
On every job
- Print process
- Digital below about a thousand, offset above it. One side or both, with spot colors where a match has to hold.
- Color
- CMYK as standard. Uncoated and kraft stocks print lighter and warmer; a spot color is the only exact match.
- Tolerance
- Cutting plus or minus 1 mm, creasing plus or minus 0.5 mm, confirmed on a plain sample before the run.
- Tooling
- A cutting die per size, made once and kept. Foil and emboss dies per artwork, also kept.
- Food contact
- Food-grade board and inks where the carton touches food, with the interior left plain.
- Sustainability
- Mono-material board wherever the product allows; recycled-content and FSC stocks; no claim printed the pack does not earn.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build ignition leads set boxes on
A folding carton is one sheet of board, so the board is the product. These are the stocks we run for cartons, what each is good at, and where it lets you down.
Natural kraft
Unbleached folding board. Warm, hides marks, costs least. Mutes color — one or two flat colors print well, photographs do not.
250–350gsm sleeves; 14–24pt cartonsWhite SBS
Solid bleached sulfate: bright, coated, the retail carton standard. Takes accurate color and every finish. Shows scuffs sooner than kraft.
14–24ptWhite lined chipboard
A recycled gray core under a white printing face. Cheaper than SBS and slightly duller; the back of the sheet stays gray.
16–24ptKraft-look coated
A kraft face over a coated inner. The natural look with a barrier behind it — the answer where oil, grease or moisture would mark plain kraft.
14–20ptRecycled-content board
Post-consumer fiber with a gray-brown cast. Right for outers and inner components; poor for bright whites and photography.
16–22ptMicro-flute E and F
A fine corrugated layer where a carton needs structure it cannot get from board — a large panel, a heavy product, a box that ships alone.
E 1.5 mm; F 0.8 mmUncoated and textured
No clay coat, or a linen or laid grain. Print reads softer and warmer; a deboss goes deeper. Photographs do not sit well on it.
280–350gsmMetalized and pearlescent
A metallic or pearl face for a shelf that needs to catch light. Costly, and it fights a photograph — a mark or a pattern suits it better.
16–20ptNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
Every finish here is a decision about light on a shelf, not about luxury.
Matte lamination
Reads considered, hides marks, takes a ballpoint.
Gloss lamination
Lifts color; glares under shop lighting.
Soft-touch
Velvet in the hand; shows fingerprints in a bag.
Hot foil
Real metal leaf — the most reliable premium signal.
Emboss / deboss
Shape with no ink; works in the dark.
Spot UV
Gloss shapes on a matte field.
Uncoated kraft
Warm, natural, mutes color.
Textured stock
Texture in the paper; cannot scuff off.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing a folding carton so the die comes out right: ignition leads set boxes
Measure the product, not the box it is in now. A carton is built around what has to fit inside it, assembled — cap on, lid fitted, folded if it folds — at its widest point in each direction. Send those three numbers and say which is which.
- Length x width x height
- Internal, always. External dimensions include the board and are what the carrier measures, not what the product needs.
- Clearance
- 2–3 mm a side for a snug fit; more where an insert or void fill goes in. A carton cut exactly to the product is slow to pack and transmits every knock.
- Board thickness
- Heavier board takes internal space from the product. It matters most on small boxes, where four walls of 24pt is a real share of the cavity.
- Varies between batches?
- Glass, textiles, molded parts and cured soap all do. Measure several and build to the largest.
- Cutting tolerance
- Plus or minus 1 mm on folding board. Confirmed on a plain sample before the run.
- Units
- Metric or imperial, as long as you say which. Mixing them in one spec is where mistakes happen.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Build your Ignition Leads Set Boxes in 3D
Pick a shape, type a size, choose a board and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about ignition leads set boxes? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
How are the leads arranged in the box?
Flat, in channels, longest to shortest, numbered to match the tags on the leads.
Will the leads be kinked?
No. They are laid in gentle curves, never folded sharply, to protect the conductor.
Do you make boxes for 4, 6 and 8 cylinder sets?
Yes, and the coil lead has its own channel in the tray.
Can the box have a window?
Yes, a clear film window that shows the lead color and boots.
Can it hang on a retail peg?
Yes, with a hang tab in the top panel.
Where does the fitment go?
On the back or a side, as a variable panel so one carton serves several engines.
What board do you use?
Boxboard for most sets; E flute for long, heavy sets.
Can you print lead diameter large?
Yes. It is one of the first things buyers compare, so it goes on the front.
Do you make economy packaging?
Yes, a header bag with a card, though it protects the boots less than a carton.
Do lead set trays come flat?
Cartons and channeled trays come flat and fold at packing.
What is the minimum order for ignition lead boxes?
100 boxes per size. Four-, six- and eight-lead sets are usually separate sizes.
How long do ignition lead boxes take?
The channeled tray is sampled with a real set first, and windows add a step. We give a date with the quote.
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