{"id":4395,"date":"2025-08-14T11:25:39","date_gmt":"2025-08-14T18:25:39","guid":{"rendered":"https:\/\/www.accordionboot.com\/shop\/?p=4395"},"modified":"2025-09-01T07:09:33","modified_gmt":"2025-09-01T14:09:33","slug":"frp-flange-box-truck-accordion-boot","status":"publish","type":"post","link":"https:\/\/www.accordionboot.com\/shop\/frp-flange-box-truck-accordion-boot\/","title":{"rendered":"How to Fix the \u201cToo Thick Wall\u201d Problem When Installing an Accordion Boot"},"content":{"rendered":"\n<p>If you need to cut an opening for your box truck pass-through and want to use the accordion boot.  But you find the wall\u2019s too thick, there\u2019s no proper flange, and the boot\u2019s spring clip has nothing to grab. Don\u2019t worry here is a solution that works.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The Problem You\u2019re Dealing With<\/h2>\n\n\n\n<p>Accordion boots are made to clamp onto a flange \u2014 a thin, uniform edge the spring steel clip can bite into. If your wall is too thick or doesn\u2019t have that edge, the boot won\u2019t attach properly. In its native state the boot has nothing to grab.<\/p>\n\n\n\n<!--more-->\n\n\n\n<h2 class=\"wp-block-heading\">The Fix: Make Your Own Flange with FRP Panel<\/h2>\n\n\n\n<p>Instead of trying to modify your truck wall, you can create a flange surface the boot <em>can<\/em> grip using <strong>FRP (Fiberglass Reinforced Panel)<\/strong>. FRP is strong, waterproof, lightweight, and easy to work with if you know how to cut it right. It is also easily available at most hardware stores.  It normally come in 4&#8242; x 8&#8242; sheets.<\/p>\n\n\n\n<p>For this project FRP is used but this is not the only material that will work with the project. Here are some alternative to also consider:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Sheet metal (16-18 Guage)<\/li>\n\n\n\n<li>Steel flat bar &#8211; May require welding<\/li>\n\n\n\n<li>Aluminum composite panel (ACP\/Dibond\u00ae style)<\/li>\n\n\n\n<li>HDPE \u201cmarine board\u201d (StarBoard\u00ae), 1\/8&#8243;<\/li>\n\n\n\n<li> Aluminum flat bar &#8211; Can have issue with radius corners<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Here\u2019s What You\u2019ll Need<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\">Materials:<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><a href=\"https:\/\/www.lowes.com\/pd\/Sequentia-48-in-x-96-in-Embossed-White-Fiberglass-Reinforced-Plastic-FRP-Wall-Panel\/1000174771\" rel=\"nofollow\">FRP panel, cut larger than your passthrough opening<\/a><\/li>\n\n\n\n<li>Heavy-duty adhesive (FRP\/metal compatible)<\/li>\n\n\n\n<li>Stainless steel screws<\/li>\n\n\n\n<li><a href=\"https:\/\/www.accordionboot.com\/shop\/product-category\/rubber-boot-seal\/\">Accordion boot with spring clip<\/a><\/li>\n\n\n\n<li><a href=\"https:\/\/www.accordionboot.com\/shop\/product\/black-polyurethane-construction-sealant-m64bl\/\">Polyurethane sealant<\/a><\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Tools:<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Circular saw with carbide-tipped blade (straight cuts)<\/li>\n\n\n\n<li>Jigsaw with fine-toothed blade (interior cutout)<\/li>\n\n\n\n<li>Hole saw<\/li>\n\n\n\n<li>Drill\/driver<\/li>\n\n\n\n<li>Measuring tape<\/li>\n\n\n\n<li>Marker<\/li>\n\n\n\n<li>Clamps<\/li>\n\n\n\n<li>Safety gear (goggles, gloves, dust mask)<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Step-by-Step: My Recommended Method<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\">1. Measure and Add Overlap<\/h3>\n\n\n\n<p>Measure your passthrough opening and add <strong>2-<\/strong>3<strong> inches all the way around<\/strong>. That\u2019s the size your FRP panel needs to be.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">2. Cut the FRP Panel<\/h3>\n\n\n\n<p>Use the right approach so you get clean, chip-free edges:<\/p>\n\n\n\n<p>When laying out the opening keep in mind that you will need at minimum a 1&#8243; radius in the corners.  Of course larger is better.  Use this as a guideline.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Circular saw with a carbide-tipped blade for the outer cut.<\/li>\n\n\n\n<li>Jigsaw with fine teeth for the inner cut where the boot will attach.<\/li>\n\n\n\n<li>Use a hole saw to define the corners<\/li>\n\n\n\n<li>Clamp the panel to keep it steady.<\/li>\n\n\n\n<li>Cut with the smooth back side facing up to minimize chipping.<\/li>\n\n\n\n<li>Sand the edges smooth and seal them with clear urethane.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">3. Bond the Panel to the Wall<\/h3>\n\n\n\n<p>Apply heavy-duty adhesive around the opening, press the FRP panel into place, then add stainless screws at even intervals for a secure mechanical hold.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">4. Seal the Edges<\/h3>\n\n\n\n<p>Run a bead of polyurethane sealant around the outside of the FRP panel. This keeps water and dust out.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">5. Attach the Accordion Boot<\/h3>\n\n\n\n<p>Now the fun part \u2014 press the boot\u2019s spring clip over your new FRP flange. You\u2019ll feel it snap in and hold firmly.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Why This Works<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>You\u2019re creating a perfect flange where none existed.<\/li>\n\n\n\n<li>FRP is thin enough for the boot to grip but strong enough to last.<\/li>\n\n\n\n<li>The seal is tight, weatherproof, and built to handle movement.<\/li>\n<\/ul>\n\n\n\n<p><strong>Bottom line:<\/strong> If your wall is too thick or doesn\u2019t have a flange, don\u2019t fight it \u2014 just make one. FRP gives you a professional finish and a boot connection you can count on.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">References<\/h2>\n\n\n\n<ol class=\"wp-block-list\">\n<li>Stabilit America. <em>How to Cut FRP Panels<\/em>. Jul 26, 2024. Available at: <a href=\"https:\/\/www.stabilitamerica.com\/blog\/how-to-cut-frp-panels\/\" target=\"_blank\" rel=\"noopener\">stabilitamerica.com<\/a>. Practical cutting methods (circular saw with carbide blade for straights; fine-tooth jigsaw for internal\/curved cuts). Accessed Aug 14, 2025.<\/li>\n\n\n\n<li>Crane Composites. <em>FRP Installation Guide (Walls\/Ceilings\/Laminated)<\/em> [PDF 6876]. Includes recommended tools (fine-tooth carbide circular saw, jigsaw) and adhesive options. Available at: <a href=\"https:\/\/cranecomposites.com\/wp-content\/uploads\/6876.pdf\" target=\"_blank\" rel=\"noopener\">cranecomposites.com<\/a>. Accessed Aug 14, 2025.<\/li>\n\n\n\n<li>NIOSH\/CDC. <em>Fibrous Glass Dust \u2013 NIOSH Pocket Guide<\/em>. Exposure limits and control guidance for fiberglass dust. Available at: <a href=\"https:\/\/www.cdc.gov\/niosh\/npg\/npgd0288.html\" target=\"_blank\" rel=\"noopener\">cdc.gov<\/a>. Accessed Aug 14, 2025.<\/li>\n\n\n\n<li>OSHA. <em>Synthetic Mineral Fibers \u2013 Overview<\/em>. General safety resources for fiberglass work (PPE and exposure evaluation). Available at: <a href=\"https:\/\/www.osha.gov\/synthetic-mineral-fibers\" target=\"_blank\" rel=\"noopener\">osha.gov<\/a>. Accessed Aug 14, 2025.<\/li>\n\n\n\n<li>YouTube (Nomad Brad). <em>BEST Cab Access Door | Box Truck Conversion<\/em>. Demonstrates a cab-to-box passthrough build; useful context for FRP-flange workaround. Available at: <a href=\"https:\/\/www.youtube.com\/watch?v=G0_DUIKae3o\" target=\"_blank\" rel=\"noopener\">youtube.com<\/a>. Accessed Aug 14, 2025.<\/li>\n<\/ol>\n\n\n<div data-alt=\"Accordion Rubber Boot Seal for connection cab and cabin for convenient pass through access.\" data-block-name=\"woocommerce\/featured-category\" data-category-id=\"45\" data-edit-mode=\"false\" data-focal-point=\"{&quot;x&quot;:0.19,&quot;y&quot;:0.22}\" class=\"wc-block-featured-category alignnone has-background-dim wp-block-woocommerce-featured-category\" style=\"min-height:500px;\"><div class=\"wc-block-featured-category__wrapper\"><div class=\"background-dim__overlay\" style=\"background-color: #000000\"><\/div><img decoding=\"async\" src=\"data:image\/gif;base64,R0lGODlhAQABAIAAAAAAAP\/\/\/ywAAAAAAQABAAACAUwAOw==\" fifu-lazy=\"1\" fifu-data-sizes=\"auto\" fifu-data-srcset=\"https:\/\/i3.wp.com\/www.accordionboot.com\/shop\/wp-content\/uploads\/2019\/05\/accordionBootRoll-1024x614.jpg?ssl=1&w=75&resize=75&ssl=1 75w, https:\/\/i3.wp.com\/www.accordionboot.com\/shop\/wp-content\/uploads\/2019\/05\/accordionBootRoll-1024x614.jpg?ssl=1&w=100&resize=100&ssl=1 100w, https:\/\/i3.wp.com\/www.accordionboot.com\/shop\/wp-content\/uploads\/2019\/05\/accordionBootRoll-1024x614.jpg?ssl=1&w=150&resize=150&ssl=1 150w, https:\/\/i3.wp.com\/www.accordionboot.com\/shop\/wp-content\/uploads\/2019\/05\/accordionBootRoll-1024x614.jpg?ssl=1&w=240&resize=240&ssl=1 240w, https:\/\/i3.wp.com\/www.accordionboot.com\/shop\/wp-content\/uploads\/2019\/05\/accordionBootRoll-1024x614.jpg?ssl=1&w=320&resize=320&ssl=1 320w, https:\/\/i3.wp.com\/www.accordionboot.com\/shop\/wp-content\/uploads\/2019\/05\/accordionBootRoll-1024x614.jpg?ssl=1&w=500&resize=500&ssl=1 500w, https:\/\/i3.wp.com\/www.accordionboot.com\/shop\/wp-content\/uploads\/2019\/05\/accordionBootRoll-1024x614.jpg?ssl=1&w=640&resize=640&ssl=1 640w, https:\/\/i3.wp.com\/www.accordionboot.com\/shop\/wp-content\/uploads\/2019\/05\/accordionBootRoll-1024x614.jpg?ssl=1&w=800&resize=800&ssl=1 800w, https:\/\/i3.wp.com\/www.accordionboot.com\/shop\/wp-content\/uploads\/2019\/05\/accordionBootRoll-1024x614.jpg?ssl=1&w=1024&resize=1024&ssl=1 1024w, https:\/\/i3.wp.com\/www.accordionboot.com\/shop\/wp-content\/uploads\/2019\/05\/accordionBootRoll-1024x614.jpg?ssl=1&w=1280&resize=1280&ssl=1 1280w, https:\/\/i3.wp.com\/www.accordionboot.com\/shop\/wp-content\/uploads\/2019\/05\/accordionBootRoll-1024x614.jpg?ssl=1&w=1600&resize=1600&ssl=1 1600w\" alt=\"Accordion Rubber Boot Seal for connection cab and cabin for convenient pass through access.\" class=\"wc-block-featured-category__background-image\" fifu-data-src=\"https:\/\/i3.wp.com\/www.accordionboot.com\/shop\/wp-content\/uploads\/2019\/05\/accordionBootRoll-1024x614.jpg?ssl=1\" style=\"object-fit: none;object-position: 19% 22%;\" \/><h2 class=\"wc-block-featured-category__title\">Rubber Boot Seal<\/h2><div class=\"wc-block-featured-category__description\"><p>You can order rubber boot material for your special project requiring pass through access. These seals are extruded from a durable EPDM synthetic rubber and incorporate a flexible spring steel clip for attachment to any flange. This material is sold by the foot. Choose between accordion boot or compression boot.<\/p>\n<\/div><div class=\"wc-block-featured-category__inner-blocks\">\n\n<div class=\"wp-block-buttons is-content-justification-center is-layout-flex wp-container-core-buttons-is-layout-a89b3969 wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button\"><a class=\"wp-block-button__link wp-element-button\" href=\"https:\/\/www.accordionboot.com\/shop\/product-category\/rubber-boot-seal\/\">Shop now<\/a><\/div>\n<\/div>\n\n<\/div><\/div><\/div>\n\n\n<h2 class=\"wp-block-heading\">Disclaimer &amp; Safety Notice<\/h2>\n\n\n\n<p>The information in this article is provided for educational purposes only. Vehicle modifications involve risk. Proceed at your own discretion and assume all responsibility for results, including any damage, injury, or loss that may occur.<\/p>\n\n\n\n<p><strong>No Professional Advice:<\/strong> This content is not engineering, mechanical, or legal advice. If you are unsure about any step, consult a qualified fabricator, body technician, or RV upfitter.<\/p>\n\n\n\n<p><strong>Warranty &amp; Returns:<\/strong> Modifying products or using them outside their standard installation (including trimming, altering embedded clips, bonding to non-flange surfaces, or fabricating custom flanges) may <em>void<\/em> any manufacturer or store warranty and <em>void<\/em> return eligibility.<\/p>\n\n\n\n<p><strong>Fitment &amp; Compatibility:<\/strong> Verify measurements, flange thickness, and material compatibility (adhesives\/sealants with EPDM, FRP, aluminum, etc.) before cutting or bonding. Perform a test fit on scrap material to confirm the boot\u2019s spring clip engages securely.<\/p>\n\n\n\n<p><strong>Structural &amp; Safety Systems:<\/strong> Cutting body panels can affect structure and safety systems. Confirm that your opening and fastener layout do not interfere with airbags, seatbelts, wiring harnesses, VIN\/emissions labels, or load-bearing members.<\/p>\n\n\n\n<p><strong>Adhesives &amp; Sealants:<\/strong> Follow manufacturer instructions, surface prep, and cure times. Use appropriate PPE and ventilation. Check for chemical compatibility and temperature ratings for your climate.<\/p>\n\n\n\n<p><strong>Weatherproofing:<\/strong> Water intrusion can cause corrosion, mold, and electrical issues. Inspect fasteners and seals periodically and re-seal as needed, especially after extreme temperatures, snow\/ice, or off-road use.<\/p>\n\n\n\n<p><strong>Tools &amp; PPE:<\/strong> Cutting FRP\/metals creates dust and sharp edges. Use eye\/hand\/respiratory protection, clamp workpieces, and follow safe tool practices.<\/p>\n\n\n\n<p><strong>Regulatory Compliance:<\/strong> Check local\/state regulations, insurance requirements, and vehicle inspection rules before performing modifications that alter the cab\/cargo barrier or body panels.<\/p>\n\n\n\n<p><strong>Affiliate\/Commercial Disclosure (Optional):<\/strong> This post may reference products sold by our company or include affiliate links. We may earn revenue from purchases, at no additional cost to you.<\/p>\n\n\n\n<script type=\"application\/ld+json\">\n{\n  \"@context\": \"https:\/\/schema.org\",\n  \"@type\": \"HowTo\",\n  \"name\": \"Create an FRP Flange so an Accordion Boot can Attach to a Too-Thick Box Truck Wall\",\n  \"description\": \"Step-by-step method to fabricate a thin, uniform flange using FRP so an accordion boot\u2019s spring clip can grip and seal a box truck pass-through.\",\n  \"mainEntityOfPage\": \"https:\/\/www.accordionboot.com\/frp-flange-box-truck-accordion-boot\/\",\n  \"image\": \"https:\/\/www.accordionboot.com\/images\/frp-flange-boot-hero-1200x630.jpg\",\n  \"supply\": [\n    { \"@type\": \"HowToSupply\", \"name\": \"FRP panel (cut larger than opening)\" },\n    { \"@type\": \"HowToSupply\", \"name\": \"Heavy-duty construction adhesive (FRP\/metal compatible)\" },\n    { \"@type\": \"HowToSupply\", \"name\": \"Stainless steel screws\" },\n    { \"@type\": \"HowToSupply\", \"name\": \"Accordion boot with spring clip\" },\n    { \"@type\": \"HowToSupply\", \"name\": \"Polyurethane sealant\" }\n  ],\n  \"tool\": [\n    { \"@type\": \"HowToTool\", \"name\": \"Circular saw with carbide-tipped blade\" },\n    { \"@type\": \"HowToTool\", \"name\": \"Jigsaw with fine-toothed blade\" },\n    { \"@type\": \"HowToTool\", \"name\": \"Drill\/driver\" },\n    { \"@type\": \"HowToTool\", \"name\": \"Measuring tape and marker\" },\n    { \"@type\": \"HowToTool\", \"name\": \"Clamps\" },\n    { \"@type\": \"HowToTool\", \"name\": \"Safety gear (goggles, gloves, dust mask)\" }\n  ],\n  \"step\": [\n    {\n      \"@type\": \"HowToStep\",\n      \"name\": \"Measure and add overlap\",\n      \"text\": \"Measure the pass-through opening and add 2 inches on all sides. This is the FRP panel size to ensure solid bonding and screw placement.\"\n    },\n    {\n      \"@type\": \"HowToStep\",\n      \"name\": \"Cut the FRP panel\",\n      \"text\": \"Use a circular saw with a carbide-tipped blade for the outer cut and a fine-toothed jigsaw for the inner opening. Clamp the panel to reduce vibration, cut with the smooth back side facing up to minimize chipping, then sand and seal edges.\"\n    },\n    {\n      \"@type\": \"HowToStep\",\n      \"name\": \"Bond the panel to the wall\",\n      \"text\": \"Apply heavy-duty adhesive around the opening. Press the FRP panel into place and add stainless screws at even intervals for a strong mechanical connection.\"\n    },\n    {\n      \"@type\": \"HowToStep\",\n      \"name\": \"Seal the perimeter\",\n      \"text\": \"Run a continuous bead of polyurethane sealant around the FRP panel\u2019s outer edge to keep water and dust out.\"\n    },\n    {\n      \"@type\": \"HowToStep\",\n      \"name\": \"Attach the accordion boot\",\n      \"text\": \"Press the boot\u2019s spring clip over the new FRP flange until it snaps into place, forming a tight, weather-resistant seal.\"\n    }\n  ]\n}\n<\/script>\n","protected":false},"excerpt":{"rendered":"<p>Running into the \u201ctoo thick wall\u201d problem when installing an accordion boot for a box truck pass-through? Here\u2019s a proven workaround: fabricate your own flange using FRP (Fiberglass Reinforced Panel). In this guide I explain what you\u2019ll need, how to cut FRP cleanly, and the exact steps\u2014measure and add 2&#8243; overlap, cut the panel and inner opening, bond it with heavy-duty adhesive, add stainless screws at even intervals, seal the perimeter, and snap the boot onto your new FRP flange. This method creates a thin, uniform edge the boot\u2019s spring clip can grip, without hacking up the original wall. It\u2019s durable, weather-tight, and perfect for DIY box truck camper conversions or mobile work rigs. Includes tool list, materials, and pro tips for cutting FRP with clean, chip-free edges.<\/p>\n","protected":false},"author":1,"featured_media":4401,"comment_status":"open","ping_status":"open","sticky":false,"template":"single-nosidebar.php","format":"standard","meta":{"fifu_image_url":"","fifu_image_alt":"","footnotes":""},"categories":[210],"tags":[],"class_list":["post-4395","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-accordion-rubber-boot"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>FRP Flange Fix for Box Truck Accordion Boot (Step-by-Step)<\/title>\n<meta name=\"description\" content=\"Wall too thick for your accordion boot to grip? Use an FRP panel to create flange. Tools, materials, cutting tips, and step-by-step install.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.accordionboot.com\/shop\/frp-flange-box-truck-accordion-boot\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"FRP Flange Fix for Box Truck Accordion Boot (Step-by-Step)\" \/>\n<meta property=\"og:description\" content=\"Wall too thick for your accordion boot to grip? Use an FRP panel to create flange. Tools, materials, cutting tips, and step-by-step install.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.accordionboot.com\/shop\/frp-flange-box-truck-accordion-boot\/\" \/>\n<meta property=\"og:site_name\" content=\"Accordion Boot Store\" \/>\n<meta property=\"article:publisher\" content=\"http:\/\/www.facebook.com\/pages\/Accordion-Boot\/226752504004202\" \/>\n<meta property=\"article:published_time\" content=\"2025-08-14T18:25:39+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2025-09-01T14:09:33+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.accordionboot.com\/shop\/wp-content\/uploads\/2025\/08\/BoxTruck-Pass-Through-Accordion-Boot-with-Flange-Modification.jpg\" \/>\n\t<meta property=\"og:image:width\" content=\"1200\" \/>\n\t<meta property=\"og:image:height\" content=\"720\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/jpeg\" \/>\n<meta name=\"author\" content=\"Accordion Boot\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:creator\" content=\"@accordionboot\" \/>\n<meta name=\"twitter:site\" content=\"@accordionboot\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Accordion Boot\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"5 minutes\" \/>\n<!-- \/ Yoast SEO plugin. -->","yoast_head_json":{"title":"FRP Flange Fix for Box Truck Accordion Boot (Step-by-Step)","description":"Wall too thick for your accordion boot to grip? Use an FRP panel to create flange. Tools, materials, cutting tips, and step-by-step install.","robots":{"index":"index","follow":"follow","max-snippet":"max-snippet:-1","max-image-preview":"max-image-preview:large","max-video-preview":"max-video-preview:-1"},"canonical":"https:\/\/www.accordionboot.com\/shop\/frp-flange-box-truck-accordion-boot\/","og_locale":"en_US","og_type":"article","og_title":"FRP Flange Fix for Box Truck Accordion Boot (Step-by-Step)","og_description":"Wall too thick for your accordion boot to grip? Use an FRP panel to create flange. 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