{"id":4442,"date":"2025-08-28T13:51:36","date_gmt":"2025-08-28T20:51:36","guid":{"rendered":"https:\/\/www.accordionboot.com\/shop\/?p=4442"},"modified":"2025-08-29T06:26:18","modified_gmt":"2025-08-29T13:26:18","slug":"how-to-fix-camper-shell-openings-for-a-perfect-accordion-boot-fit","status":"publish","type":"post","link":"https:\/\/www.accordionboot.com\/shop\/how-to-fix-camper-shell-openings-for-a-perfect-accordion-boot-fit\/","title":{"rendered":"How to Fix Camper Shell Openings for a Perfect Accordion Boot Fit"},"content":{"rendered":"\n<p>There have been occasions where someone gets a used fiberglass camper shell. For the most part the shell will fit the truck but there are instances where opening doesn\u2019t match the truck\u2019s rear window or is damaged. Here this thing, if you\u2019re planning to use an accordion boot to connect the cab and the camper, you will run into problems<\/p>\n\n\n\n<p>Here is why, The accordion boot only works if the two openings are the <strong>exact same <strong>outside perimeter<\/strong><\/strong> <strong>measurement and shape <\/strong>. If they\u2019re off, even by a little, the boot will twist, buckle, or leave gaps. That means it won&#8217;t seal properly and creates a faulty pass-through connection.<\/p>\n\n\n\n<p>Luckily, there\u2019s a fix. I found this video that does a good job of fixing the problem fabricating a new wall with fiberglass:<\/p>\n\n\n\n<!--more-->\n\n\n\n<figure class=\"wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-16-9 wp-has-aspect-ratio\"><div class=\"wp-block-embed__wrapper\">\n<iframe loading=\"lazy\" title=\"MAKING THIS CAMPER SHELL FIT LIKE FACTORY !\" width=\"980\" height=\"551\" src=\"https:\/\/www.youtube.com\/embed\/LtPe1zf0lDQ?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe>\n<\/div><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Why the Opening Matters<\/h2>\n\n\n\n<p>The accordion boot is a flexible gasket. It\u2019s designed to fill the gap  between two flat, parallel surfaces that have the same outline. If the camper shell\u2019s opening is bigger, smaller, or shaped differently than the truck window, the boot will never seat correctly. Instead of sealing, it buckles, folds, or pulls away at the corners. The best fix is to modify the camper shell&#8217;s front wall.  Unfortunately &#8220;close enough&#8221; will create installation headaches.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Here&#8217;s How to Do It<\/h2>\n\n\n<div class=\"saswp-how-to-block-section\"><div class=\"saswp-how-to-block-steps\"><p>Step-by-Step Overview to create a fiberglass wall to receive accordion boot<\/p><ol><li><h3 class=\"\"> Measure and Template <\/h3><p class=\"saswp-how-to-step-text\">Measure your truck\u2019s rear window opening precisely. Cut a cardboard template until it matches perfectly. This is your guide.<\/p><\/li><li><h3 class=\"\"> Frame the Gap <\/h3><p class=\"saswp-how-to-step-text\">If the camper shell opening is too large, build up a support frame with plywood or foam inside the opening. Make the form larger to allow you to fine tune the opening with matching both openings<\/p><\/li><li><h3 class=\"\"> Prepare the surface <\/h3><p class=\"saswp-how-to-step-text\">Using sandpaper sand the camper shell fiberglass in the are you are creating the new wall. This will help the new fiberglass bond<\/p><\/li><li><h3 class=\"\"> Apply Fiberglass  <\/h3><p class=\"saswp-how-to-step-text\">Apply resin, lay down fiberglass cloth, and roll out bubbles. Keep it flat and smooth. To create a bond overlap fiberglass to existing shell. <\/p><\/li><li><h3 class=\"\"> Create the right thickness <\/h3><p class=\"saswp-how-to-step-text\">Add 2\u20133 layers (or more, depending on thickness). Let each cure properly. target the thickness to be about 1\/8&#8243;<\/p><\/li><li><h3 class=\"\"> Trim and Finish <\/h3><p class=\"saswp-how-to-step-text\"> Allow the fiberglass to partially cure and use the utility knife to remove the excess. Once cured, trim with jigsaw or use a grinder on the edges to your template. Sand smooth.<\/p><\/li><li><h3 class=\"\"> Smooth Surface <\/h3><p class=\"saswp-how-to-step-text\"> If needed to smooth out surface use body filler to fill in dips.  Note: the smoother and level the the fiberglass<\/p><\/li><li><h3 class=\"\"> Test Fit <\/h3><p class=\"saswp-how-to-step-text\">Before final installation, test the boot against both sides to confirm alignment. Make any fine adjustments.<\/p><\/li><\/ol><\/div><div class=\"saswp-how-to-block-tools\"><h5>Tools<\/h5><ul><li>tape measure<\/li><li>utility knife<\/li><li>saw\/jigsaw<\/li><li>rollers and brushes<\/li><li>grinder<\/li><li>safety gear (respirator, gloves, goggles).<\/li><\/ul><\/div><div class=\"saswp-how-to-block-material\"><h5>Materials<\/h5><ul><li><a href=\"https:\/\/amzn.to\/47kPDAa\" target=\"_blank\" rel=\"noreferrer noopener sponsored nofollow\">Fiberglass cloth or mat<\/a><\/li><li><a href=\"https:\/\/amzn.to\/47kPDAa\" target=\"_blank\" rel=\"noreferrer noopener sponsored nofollow\">Polyester Resin and hardener<\/a><\/li><li>Paint (to finish it)<\/li><li><a href=\"https:\/\/amzn.to\/426YQIN\" target=\"_blank\" rel=\"noreferrer noopener sponsored nofollow\">Body filler<\/a><\/li><li>Something to create a form to apply fiberglass. Any flat thin panel can work.  Plywood, foam board, Masonite<\/li><li>Masking Tape<\/li><li>sandpaper <\/li><\/ul><\/div><\/div>\n\n\n<h2 class=\"wp-block-heading\">Pro Tips<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Always scuff and sand surfaces before laying fiberglass\u2014bonding depends on it.<\/li>\n\n\n\n<li>Ventilate your workspace. Resin fumes aren\u2019t something you want to breathe.<\/li>\n\n\n\n<li>Double-check your perimeter measurement and size before glassing. Even a \u00bc inch off can ruin the boot fit.<\/li>\n\n\n\n<li>It is better to have to much material than too litter because it is easier to remove fiberglass than to add more.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Why This Fix Works<\/h2>\n\n\n\n<p>By fabricating the front wall of your camper shell, you bring the opening into perfect alignment with your truck\u2019s rear window. That allows the accordion boot to fit perfectly all the way around. No twisting, no gaps, no buckling.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Final Thoughts<\/h2>\n\n\n\n<p>If your shell opening and truck window don\u2019t match, the boot won\u2019t work\u2014simple as that. But with a little fiberglass work, you can rebuild the shell\u2019s front wall to match exactly. The video above walks through the process, and once you\u2019ve done it, your accordion boot will seat like it should, giving you a clean, weatherproof pass-through.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Frequently Asked Questions<\/h2>\n\n\n<div class=\"saswp-faq-block-section\"><ol style=\"list-style-type:none\"><li style=\"list-style-type: none\"><h3 class=\"\">Why does the camper shell opening need to match the truck window?<\/h3><p class=\"saswp-faq-answer-text\">The accordion boot only seals correctly when both openings are the same size and shape on the outside perimeter. If they don\u2019t match, the boot will twist, buckle, or leave gaps that let in water, dust, and noise.<\/p><li style=\"list-style-type: none\"><h3 class=\"\">Can I make small adjustments to the accordion boot instead of fiberglass?<\/h3><p class=\"saswp-faq-answer-text\">If the perimeter is off by more than a fraction of an inch you will have problems fitting the boot. Fiberglassing a new wall section ensures a solid, factory-style fit.<\/p><li style=\"list-style-type: none\"><h3 class=\"\">Do I need special tools to work with fiberglass?<\/h3><p class=\"saswp-faq-answer-text\">Not really. You\u2019ll need basics like a saw or jigsaw, rollers, brushes, mixing cups, and sandpaper. Safety gear is essential: a respirator, gloves, and goggles.<\/p><li style=\"list-style-type: none\"><h3 class=\"\">How many fiberglass layers should I use?<\/h3><p class=\"saswp-faq-answer-text\">To get good results  you will need about  2\u20134 layers of fiberglass cloth. For extra strength, especially on larger openings, you can add more layers.<\/p><li style=\"list-style-type: none\"><h3 class=\"\">What if my camper shell opening is larger than my truck window?<\/h3><p class=\"saswp-faq-answer-text\">In that case, you\u2019ll need to \u201cshrink\u201d the opening by building up the perimeter with fiberglass. The goal is to reshape the shell wall until it matches your truck&#8217;s rear window opening exactly.<\/p><li style=\"list-style-type: none\"><h3 class=\"\">Can I paint over the fiberglass when I\u2019m done?<\/h3><p class=\"saswp-faq-answer-text\">Yes. Once cured and sanded smooth, you can coat the fiberglass with paint for a factory look.  For best results use primer and matching paint to blend it with your camper shell.<\/p><\/ul><\/div>\n\n\n<div class=\"wp-block-group\"><div class=\"wp-block-group__inner-container is-layout-flow wp-block-group-is-layout-flow\"><div data-block-name=\"woocommerce\/featured-category\" data-category-id=\"45\" data-edit-mode=\"false\" 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=\"Rubber Boot Seal\" 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: 50% 50%;\" \/><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><\/div><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Resources<\/h2>\n\n\n\n<p>Here are some helpful links and references if you\u2019re planning to modify your camper shell or work with fiberglass:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><a href=\"https:\/\/www.westsystem.com\/instruction\/instruction-manuals\/fiberglass-boat-repair-maintenance\/\" target=\"_blank\" rel=\"noreferrer noopener nofollow\">West System: Fiberglass Boat Repair &amp; Maintenance Guide<\/a> \u2013 clear instructions on resin mixing, fiberglass cloth, and curing techniques.<\/li>\n\n\n\n<li><a href=\"http:\/\/Fiberglass Supply \u2013 How to Work with Fiberglass\" target=\"_blank\" rel=\"noreferrer noopener nofollow\">How to Work with Fiberglass<\/a> \u2013 practical DIY tips for working with fiberglass materials.<\/li>\n\n\n\n<li><a href=\"https:\/\/www.truckcampermagazine.com\/question-of-the-week\/poll-results-pass-through-windows\/\" target=\"_blank\" rel=\"nofollow noopener\">Truck Camper Magazine \u2013 Pass Through Windows Survey<\/a> \u2013 insights into why truck camper owners use pass-throughs.<\/li>\n\n\n\n<li><a href=\"https:\/\/fiberglasswarehouse.com\/blogs\/news\/safety-first\" target=\"_blank\" rel=\"noreferrer noopener nofollow\">Safety First! Working with Fiberglass and Resin Products<\/a> \u2013 By following these simple tips, you can make safety a top priority while enjoying your fiberglass and resin projects.<\/li>\n\n\n\n<li><a href=\"https:\/\/www.instructables.com\/Repairing-Fiberglass\/\" target=\"_blank\" rel=\"noreferrer noopener nofollow\">Repairing Fiberglass<\/a> &#8211; Step by step instructions on doing fiberglass repairs.<\/li>\n<\/ul>\n\n\n\n<p><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Buying a used camper shell is a great way to save money, but if the front opening doesn\u2019t match your truck\u2019s rear window, your accordion boot won\u2019t seal properly. The fix? Rebuild the shell\u2019s front wall with fiberglass so the openings line up exactly. This guide (with video) shows how to get a clean, factory-fit installation that keeps out leaks, dust, and noise.<\/p>\n","protected":false},"author":1,"featured_media":4446,"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-4442","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 v27.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>How to Fix Camper Shell Openings for a Perfect Accordion Boot Fit<\/title>\n<meta name=\"description\" content=\"Learn how to modify fiberglass camper shell so the front opening matches your truck cab window\u2014ensuring your accordion boot fits properly.\" \/>\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\/how-to-fix-camper-shell-openings-for-a-perfect-accordion-boot-fit\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"How to Fix Camper Shell Openings for a Perfect Accordion Boot Fit\" \/>\n<meta property=\"og:description\" content=\"Learn how to modify fiberglass camper shell so the front opening matches your truck cab window\u2014ensuring your accordion boot fits properly.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.accordionboot.com\/shop\/how-to-fix-camper-shell-openings-for-a-perfect-accordion-boot-fit\/\" \/>\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\" 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