diff --git a/orchestrator/src/server/services/pdf-tailoring.test.ts b/orchestrator/src/server/services/pdf-tailoring.test.ts
new file mode 100644
index 0000000..ab8ae6e
--- /dev/null
+++ b/orchestrator/src/server/services/pdf-tailoring.test.ts
@@ -0,0 +1,165 @@
+
+import { describe, it, expect, vi, beforeEach } from 'vitest';
+import * as projectSelection from './projectSelection.js';
+
+// Define mock data in hoisted block
+const { mocks, mockProfile } = vi.hoisted(() => {
+    const profile = {
+        sections: {
+            summary: { content: 'Original Summary' },
+            skills: { items: ['Original Skill'] },
+            projects: { 
+                items: [
+                    // Start with visible=true to test if they get hidden
+                    { id: 'p1', name: 'Project 1', visible: true },
+                    { id: 'p2', name: 'Project 2', visible: true }
+                ] 
+            }
+        },
+        basics: { headline: 'Original Headline' }
+    };
+
+    return {
+        mockProfile: profile,
+        mocks: {
+            readFile: vi.fn(), 
+            writeFile: vi.fn(),
+            mkdir: vi.fn().mockResolvedValue(undefined),
+            access: vi.fn().mockResolvedValue(undefined),
+            unlink: vi.fn().mockResolvedValue(undefined),
+        }
+    };
+});
+
+// Configure base mock implementations
+mocks.readFile.mockResolvedValue(JSON.stringify(mockProfile));
+mocks.writeFile.mockResolvedValue(undefined);
+
+vi.mock('fs/promises', async () => {
+    return {
+        default: mocks,
+        ...mocks
+    };
+});
+
+vi.mock('fs', () => ({
+    existsSync: vi.fn().mockReturnValue(true),
+    default: { existsSync: vi.fn().mockReturnValue(true) }
+}));
+
+vi.mock('../repositories/settings.js', () => ({
+  getSetting: vi.fn().mockResolvedValue(null),
+}));
+
+vi.mock('./projectSelection.js', () => ({
+    pickProjectIdsForJob: vi.fn().mockResolvedValue([]),
+}));
+
+vi.mock('./resumeProjects.js', () => ({
+    extractProjectsFromProfile: vi.fn().mockReturnValue({
+        catalog: [],
+        selectionItems: [
+            { id: 'p1', name: 'Project 1' },
+            { id: 'p2', name: 'Project 2' }
+        ]
+    }),
+    resolveResumeProjectsSettings: vi.fn().mockReturnValue({
+        resumeProjects: {
+            lockedProjectIds: [],
+            aiSelectableProjectIds: ['p1', 'p2'],
+            maxProjects: 3
+        }
+    })
+}));
+
+vi.mock('child_process', () => ({
+    spawn: vi.fn().mockImplementation(() => ({
+        stdout: { on: vi.fn() },
+        stderr: { on: vi.fn() },
+        on: vi.fn().mockImplementation((event, cb) => {
+            if (event === 'close') cb(0);
+            return {};
+        }),
+    })),
+    default: {
+        spawn: vi.fn().mockImplementation(() => ({
+            stdout: { on: vi.fn() },
+            stderr: { on: vi.fn() },
+            on: vi.fn().mockImplementation((event, cb) => {
+                if (event === 'close') cb(0);
+                return {};
+            }),
+        }))
+    }
+}));
+
+import { generatePdf } from './pdf.js';
+
+describe('PDF Service Tailoring Logic', () => {
+    beforeEach(() => {
+        vi.clearAllMocks(); 
+        
+        // Reset default behaviors
+        mocks.readFile.mockResolvedValue(JSON.stringify(mockProfile));
+        mocks.writeFile.mockResolvedValue(undefined);
+    });
+
+    it('should use provided selectedProjectIds and BYPASS AI selection', async () => {
+        const tailoredContent = { summary: 'New Sum', headline: 'New Head', skills: [] };
+        
+        await generatePdf('job-1', tailoredContent, 'Job Desc', 'base.json', 'p2');
+
+        // 1. pickProjectIdsForJob should NOT be called
+        expect(projectSelection.pickProjectIdsForJob).not.toHaveBeenCalled();
+
+        // 2. Verify writeFile content
+        expect(mocks.writeFile).toHaveBeenCalled();
+        const callArgs = mocks.writeFile.mock.calls[0];
+        const savedResumeJson = JSON.parse(callArgs[1] as string);
+        
+        const projects = savedResumeJson.sections.projects.items;
+        const p1 = projects.find((p: any) => p.id === 'p1');
+        const p2 = projects.find((p: any) => p.id === 'p2');
+
+        expect(p2.visible).toBe(true);
+        expect(p1.visible).toBe(false); 
+
+        // 3. Verify Summary Update
+        const summary = savedResumeJson.sections.summary.content;
+        expect(summary).toBe('New Sum'); 
+    });
+
+    it('should handle comma-separated project IDs correctly', async () => {
+        await generatePdf('job-2', {}, 'desc', 'base.json', 'p1, p2 ');
+
+        expect(mocks.writeFile).toHaveBeenCalled();
+        const callArgs = mocks.writeFile.mock.calls[0];
+        const savedResumeJson = JSON.parse(callArgs[1] as string);
+        const projects = savedResumeJson.sections.projects.items;
+
+        expect(projects.find((p: any) => p.id === 'p1').visible).toBe(true);
+        expect(projects.find((p: any) => p.id === 'p2').visible).toBe(true);
+    });
+    
+    it('should fall back to AI selection if selectedProjectIds is null/undefined', async () => {
+        // Setup AI selection mock for this test
+        vi.mocked(projectSelection.pickProjectIdsForJob).mockResolvedValue(['p1']);
+
+        await generatePdf('job-3', {}, 'desc', 'base.json', undefined);
+
+        expect(projectSelection.pickProjectIdsForJob).toHaveBeenCalled();
+        
+        expect(mocks.writeFile).toHaveBeenCalled();
+        const callArgs = mocks.writeFile.mock.calls[0];
+        const savedResumeJson = JSON.parse(callArgs[1] as string);
+        
+        const p1 = savedResumeJson.sections.projects.items.find((p: any) => p.id === 'p1');
+        const p2 = savedResumeJson.sections.projects.items.find((p: any) => p.id === 'p2');
+
+        expect(p1.visible).toBe(true);
+        expect(p2.visible).toBe(false);
+        
+        const visibleCount = savedResumeJson.sections.projects.items.filter((p:any) => p.visible).length;
+        expect(visibleCount).toBe(1);
+    });
+});