How to Set Up a DIY Overland Rig with Pass Through Access

Use an Accordion Boot for Full Pass-Through Convenience

Building your own DIY overland rig is one of the most rewarding projects you can take on as an outdoor adventurer. Whether you’re exploring backroads, camping off-grid, or just looking for more freedom, converting your truck into a reliable, comfortable overland setup gives you flexibility and control over your journey.

But one feature that very important — and makes a big difference — is cab access. Being able to move between the cab and the camper without stepping outside adds a whole new level of comfort, especially when it’s cold, raining, or you’re stealth camping.

So, how do you make it happen? Simple: install an accordion boot.

Why Cab Access Matters in an Overland Rig

Before we get into the how-to, let’s look at why connecting your cab and camper shell is such a smart upgrade:

• Stay dry in bad weather (no climbing out to access your sleeping area)
• Pass gear, tools, or snacks without getting out
• Use your cab as a heated or cooled extension of your sleeping space
• Increase airflow between compartments with fans or vents
• Better stealth camping (no need to exit the cab at night)

This kind of integration turns your overland truck into a mini expedition vehicle — and the key is sealing that gap securely and cleanly.

What Is an Accordion Boot?

An accordion boot is a flexible rubber connector that seals the space between your truck’s cab and rear camper compartment. It flexes like a bellows and allows for:

• Weatherproofing
• Dust and noise reduction
• Pass-through access

Ours are made of durable black EPDM rubber with a built-in spring steel clip to snap securely onto the window frame of your truck cab and camper shell. Installation is DIY-friendly and requires only a few basic tools.

Accordion boots are universal fit and can be adapted for may different vehicle configurations

How to Add a Pass-Through

Here’s a quick overview of how to add this feature to your build:

1. Check Your Access Opening

• Both opening must be the exact same size
• Ideally that should be aligned with each other.
• There needs to be a flange or thin wall to allow the grooved metal clip to attach. Modification or fabrication my be required.

2. Measure Your Gap

• Use a tape measure to determine the distance between the cab and shell.
• Also measure the perimeter around the access opening to ensure a proper fit.

Use our Boot Opening Calculator to get accurate sizing!

3. Install the Boot

• Clean the mounting surfaces to make sure they are clear of dust or oil.
• Slide the spring steel edge over the flange or lip of the access opening
• Tap the boot with a rubber mallet to secure the fit.

Full install guide here: How to Install an Accordion Boot »

Bonus Tips for a Better DIY Overland Rig

While you’re adding a pass-through, consider upgrading your rig with:

• Insulated window panels for warmth
• 12V fans or vent systems for airflow between cab and camper
• Battery-powered LED lighting in both compartments
• Modular storage to store your gear

Your goal should be a seamless transition between the cab and the camper shell — and the accordion boot is the centerpiece of that design.

Get the Right Boot for Your Build

Not sure which boot size you need? No problem.
Use our Calculator Tool or Contact Us for help.

Then check out our premium, made-in-USA accordion boots designed for rugged builds and real adventure:

Wrap-Up: Make Your Rig Smarter, Not Just Bigger

Adding a cab-to-camper pass-through is one of those simple mods that completely changes the feel of your overland setup. It connects your living space, makes your gear more accessible, and adds serious weather protection — all with a single, affordable upgrade.

Start your overland adventure the smart way — with full cab access and a boot that’s built to last.