How do I Mark the area to cut?

You need to tape off the area for the best reference for cutting. You’ll want to take some GOOD measurements for each wall and then use the tape to mark the area. Measure twice cut once…I’m sure you’ve heard that before. It is recommend you start .5 inch up from the bottom of the bed floor since the boot needs material to grip onto.

How big do I cut the hole?

This is completely up to you. A bigger cut yields the advantages of having more air flow into the cab as well as being able to slid a box into the cabin if you so desire. A smaller cut is more stealth and easier to weld back up if you decided to sell your truck. Note – keep the metal patches you cut out of your truck as you or someone else can easily weld them back into place if you want to return it to “almost” original condition.

What tool is the best one to use for cutting?

There area variety of tools that can be used to cut the opening which included a rotozip, air grinder, sawzal and hand drill with grinder attachment. The fastest tool is the rotozip. With a good bit it will sail through the metal like butter.The sawzal is the 2nd second choice followed by the air grinder and hand drill. For control definitely the air/hand grinders…since they’re slower its easier to control their movements. The rotozip was 2nd followed by the sawzal in last place, mainly because the blades bend a lot and its hard to cut through one wall at a time with it because of motion the blade takes and extreme forces.

What is accordion boot?

An accordion boot is a thick rubber gasket mainly used for toppers or ventilation on trucks to join to separate compartments that would be exposed to the outside. The edges of the boot have metal clips in them that help grip onto the metal. For a conventional cut-through a boot that is 2.5-3” wide is more then enough. This will be compressed when applied and since the boot can easily stretch to 2x its compressed width you’ll have more then enough for bed travel.

Cut-Through FAQ

Step 1 – Gather Tools and Prepare

Before you start cutting into your vehicle, make sure you have everything you need:

Get Tools and Materials:

Marking tool – Masking tape or Sharpie to outline the area to cut
Cutting tool – One of the following:
- Plasma cutter
- Air grinder
- Jigsaw
- Rotozip
- Sawzall
Hole saw – For rounding corners and initiating cuts
Accordion boot – To seal the opening between cab and bed
Tarp or blanket – To catch metal shavings inside your vehicle

Step 2 – Cut the Opening and Install the Boot

Mark off the cut area with masking tape or a Sharpie.
Use your selected cutting tool to make straight, careful cuts.
Important: Round off all four corners using a hole saw. The accordion boot will not seat properly in 90° corners.
Smooth and clean the edges of the cut to prevent tearing the boot.
Fit the boot carefully, especially around any structural ribs in the cab wall.
Be patient. Proper fitting may take 30–40 minutes.

Measuring the accordion boot

Step 3 – Seal and Test

Align the box or camper shell as close to the cab wall as possible.
Ensure a tight seal to prevent audio pressure loss (especially important if installing subwoofers).
A tight seal improves sound clarity and volume by preventing sound from escaping into the truck bed.

Questions and Answers

Frequently Asked Questions

How do I Mark the area to cut?
You need to tape off the area for the best reference for cutting. You’ll want to take some GOOD measurements for each wall and then use the tape to mark the area. Measure twice cut once…I’m sure you’ve heard that before. It is recommend you start .5 inch up from the bottom of the bed floor since the boot needs material to grip onto.
How big do I cut the hole?
This is completely up to you. A bigger cut yields the advantages of having more air flow into the cab as well as being able to slid a box into the cabin if you so desire. A smaller cut is more stealth and easier to weld back up if you decided to sell your truck. Note – keep the metal patches you cut out of your truck as you or someone else can easily weld them back into place if you want to return it to “almost” original condition.
What tool is the best one to use for cutting?
There area variety of tools that can be used to cut the opening which included a rotozip, air grinder, sawzal and hand drill with grinder attachment. The fastest tool is the rotozip. With a good bit it will sail through the metal like butter.The sawzal is the 2nd second choice followed by the air grinder and hand drill. For control definitely the air/hand grinders…since they’re slower its easier to control their movements. The rotozip was 2nd followed by the sawzal in last place, mainly because the blades bend a lot and its hard to cut through one wall at a time with it because of motion the blade takes and extreme forces.
What is accordion boot?
An accordion boot is a thick rubber gasket mainly used for toppers or ventilation on trucks to join to separate compartments that would be exposed to the outside. The edges of the boot have metal clips in them that help grip onto the metal. For a conventional cut-through a boot that is 2.5-3” wide is more then enough. This will be compressed when applied and since the boot can easily stretch to 2x its compressed width you’ll have more then enough for bed travel.

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