Oversized Canvas

Yes, you are correct. The rolled canvas will not include the canvas frame. :)

Unfortunately, even if we are to use 0.75" for the thickness, it will still be too oversized.

We custom make each box for the larger sizes. The guidelines we use for sizing the box is to add an extra inch to the width and height of the canvas. If the canvas is 0.75" thick, then the box height will be 2 inches. If the canvas is 1.5" thick, the box height will be 3 inches. 

For example, a 48x72x1.5 canvas will have a box size of 49x73x3.

The length is defined as the longest dimension of the box, the width is the second largest dimension, and the height is the smallest dimension of the box. FedEx calculates a shipping dimension by taking the length of the box and adding the girth (2 times the width plus height). The shipping dimension for the 48x72x1.5 canvas will be 73 (length) + 2*(49 width + 3 height) = 73+2*(49+3) = 177. Unfortunately, the limit for FedEx Ground is 165. Anything larger than that will have to be shipped via freight. If we change it to 0.75" thickness, the dimensional calculation will be 73+2*(48+2) = 173 which unfortunately will still be too large for Ground. 

Based on these calculations, the maximum size we can ship with Ground is about 42x72x1.5 (box size of 43x73x3 -> dimensional size of 165). This is a little too close to the limit, so I would recommend the 40x72x1.5 instead. Please note that for these larger sizes, we recommend the 1.5" thick stretcher bars because the 0.75" will be more prone to twisting and warping.

I strongly recommend you get the rolled canvas instead since the size of the stretched canvas would prevent us from being able to ship it via FedEx ground. We would have to use a freight company and the cost of trucking ranges between $300-400.