Can I install an accordion boot on a box truck without a flange?

If no flange or thin wall is present you’ll need to fabricate a flange around the opening using materials like aluminum, steel or other rigid material that is about 1/8" thick. The accordion boot’s spring steel clip needs something to grip, so creating a rigid mounting surface is essential for a secure fit.

Will the accordion boot keep rain and dust out?

Yes, when properly installed, the accordion boot creates a weatherproof and dust-resistant seal between the cab and the box.

How much movement can the accordion boot handle?

Accordion boots are designed to flex and compress, typically accommodating various gap sizes depending on the size boot with some movement. This is the primary reason for this item where the cab and box flex slightly while driving. An estimate for the flex is is the size of the gap minus the maximum stretch of the accordion size.

Is the accordion boot good for insulation in cold or hot weather?

While the boot itself doesn’t offer thermal insulation, it does seal off airflow, which helps maintain climate control between compartments. For additional thermal insulation you can add other forms of insulating materials over the pass-through area for better temperature regulation.

How to Install an Accordion Boot Box Truck Conversion

DIY Tips: Converting a Box Truck Into a Livable Rig

In this article we will look at converting a box truck into a livable space. This is great for expedition vehicles , mobile business, or off-grid travel. This is a popular DIY project. But one upgrade that’s totally worth the effort is a pass-through opening between the cab and the box for an accordion boot box truck conversion.

This makes the build feel more like an RV or van. It also provide you with convenience. The best way to seal that pass-through is using a flexible, weatherproof accordion boot.

We will show you how to connect your box truck cab to the rear box using an accordion boot . Along with that how to overcome one of the biggest challenges: lack of a flange on the box wall.

Why Create a Cab-to-Box Pass-Through?

If you are living in your box truck or using it for mobile work, a pass-through provides major advantages:

Stay inside during bad weather
Access your gear or living space from the driver’s seat
Improve airflow or install wiring/fan systems
Enhance stealth camping and safety

Without a proper seal between the cab and box, though, you’re exposing yourself to:

Rain and wind leaks
Dust and exhaust fumes
Temperature loss
Increased road noise

What Is an Accordion Boot?

An accordion boot is a flexible rubber gasket that compresses and expands to fill the gap between the truck cab and box,

The accordion boot is made with rugged EPDM rubber with a built-in spring steel clip. it creates a seal between the gap while allowing flex and movement. This is the same item used in truck camper setups. accordion boots are now popular among DIY mobile living conversions.

Step-by-Step: How to Install an Accordion Boot in a Box Truck

Measure the Perimeter and Gap
Determine the size and placement of the pass through opening

Use a tape measure to find the perimeter of the opening

Measure the gap distance between the cab and box — depending on the truck the gap can vary between 2″ and 6″

The cab and box opening perimeters must be similar in size for the boot to seal properly
Cut the Openings in the Cab and Box
Plan and mark a pass-through opening that matches between the cab rear wall and the front of the box

Use a jigsaw or reciprocating saw to cut out the two opening

Take note of any wiring or structural supports

Deburr and clean the edges
Address the Flange Problem on the Box
Some truck boxes are flat panel walls with no built-in flange. Since the accordion boot uses a spring steel clip to grab onto a flange, you’ll might need to add one yourself. This is a case by case situation

Here are some ideas to create a flange:

Use 1/8″ thick aluminum, fiberglass or steel bar stock to create a mounting flange around the opening

Cut strips to match each side of the opening and fasten with rivets or self-tapping screws

Paint or seal to prevent corrosion

Ensure the flange lip is wide enough (at least 1/2″) for the boot to grip

Tip: Add a bead of sealant behind the flange strip helps with waterproofing and adhesion
Install the Accordion Boot
Starting at the middle bottom of the opening slide one side of the boot over the cab sheet metal

Slide the other side on the box side

Press the boot slightly to secure it. You can also use a soft mallet to tap down the boot.

Work your way around the opening until the ends meet.

Trim the ends so the the section with the clip butt up to each other and the accordion section overlap a couple of inches.

Find the Right Accordion Boot Box Truck Conversion

Our accordion boots are crafted from EPDM rubber with a spring steel embedded into the rubber for fast, flexible mounting. They work great for box trucks, DIY RVs, and custom conversions.

Final Thoughts Box Truck Conversion

A cab-to-box pass-through is one of the best upgrades you can add to a DIY box truck conversion. Whether you’re building a stealth camper, mobile workshop, or rolling tiny home, the accordion boot gives you the access between compartments. It provide a clean, functional, and weather-tight solution.

Can I install an accordion boot on a box truck without a flange?
If no flange or thin wall is present you’ll need to fabricate a flange around the opening using materials like aluminum, steel or other rigid material that is about 1/8″ thick. The accordion boot’s spring steel clip needs something to grip, so creating a rigid mounting surface is essential for a secure fit.
Will the accordion boot keep rain and dust out?
Yes, when properly installed, the accordion boot creates a weatherproof and dust-resistant seal between the cab and the box.
How much movement can the accordion boot handle?
Accordion boots are designed to flex and compress, typically accommodating various gap sizes depending on the size boot with some movement. This is the primary reason for this item where the cab and box flex slightly while driving. An estimate for the flex is is the size of the gap minus the maximum stretch of the accordion size.
Is the accordion boot good for insulation in cold or hot weather?
While the boot itself doesn’t offer thermal insulation, it does seal off airflow, which helps maintain climate control between compartments. For additional thermal insulation you can add other forms of insulating materials over the pass-through area for better temperature regulation.

Spread the love