Sunny Shutter Inc. product standards
Window blind fit, light gaps and finish expectations.
A clear guide to the normal operating clearances, dimensional tolerances and visual characteristics of custom blinds, shades, shutters and curtains.
Important: A visible side gap does not automatically mean a shade was measured or manufactured incorrectly. Fabric is intentionally narrower than the cassette, tube or headrail so the product can operate without rubbing or binding.
The short answer
Custom-made does not mean zero clearance.
A made-to-measure window covering is produced for a specific opening, mount type and control system. It still needs enough room for brackets, end caps, chains, motors, fabric travel and minor variation in the window opening.
Why side gaps exist
Clearance protects the product.
If the fabric were cut to the full cassette width, it could scrape the window trim, rub against hardware, fray, telescope on the tube or stop moving correctly.
The chain, clutch, wand or motor may require more space than the idle side.
Uneven drywall, bowed trim, handles, screens and non-square openings affect the visible reveal.
Strong backlighting makes any edge clearance look larger than it appears under normal room lighting.
Sunny standard zebra reference
Four practical fit checkpoints.
These figures summarize a standard SUNNY zebra-blind configuration. Product family, control type, motor, cassette, mounting method and written order specifications may require different deductions.
The combined installation clearance around a standard inside-mounted cassette may be up to approximately 1/4 inch.
The fabric may be up to approximately 7/8 inch narrower than the cassette in a standard configuration to accommodate operation and hardware.
The bottom bar may be up to approximately 3/8 inch narrower than the cassette so it can travel and align without contacting the surrounding trim.
A finished component may vary up to approximately 1/8 inch from the stated production reference, subject to the product specification.
These are product-reference points, not a promise of zero light leakage or perfectly equal left/right reveals. The confirmed order and product-specific production standard govern where they differ.
Product-specific expectations
Different systems need different clearances.
The correct comparison is between the installed product and the specification for that exact product—not between two unrelated shade types.
Layer alignment changes as the shade moves.
Two fabric layers travel around a tube and bottom bar. Minor band alignment variation, edge reveal and control-side asymmetry are inherent to the system.
- Fabric is narrower than the cassette
- Room-darkening fabrics still allow edge light
- Very wide shades may show natural fabric movement
The roll needs side clearance.
The fabric must clear the clutch or motor, idle pin and brackets. An inside-mounted roller shade commonly shows more side light than a cellular shade or framed shutter.
- Control side may be wider
- Open-roll and cassette deductions differ
- Solar openness affects glare, view and privacy
Soft materials are not rigid panels.
Honeycomb shades require edge clearance to travel freely. Roman shades are sewn textile products, so fold memory, gentle bowing and small visual variation can occur.
- Inside mounts retain a small perimeter reveal
- Fabric lots may vary slightly in colour or texture
- Heat, humidity and width affect soft fabrics
Frames and textiles have their own fit rules.
Shutters need installation and panel-swing clearance. Drapery and sheers are evaluated by approved fullness, finished drop, stack-back and selected floor treatment.
- Perimeter reveal may follow the opening
- Caulking or trim work applies only when included
- Floor clearance or puddling must be selected in advance
Motor hardware can change the deduction.
Motor type, drive side, charging access, end caps and power configuration can affect the finished width and the balance of the side gaps.
- Charging-port location is model dependent
- Battery and hardwired systems differ
- Small stopping-position variation may require limits to be reset
Eligibility depends on the window recess.
The optional No Drill system is available only for select compatible shades and suitable openings. Recess depth, mounting surface, size and window condition must be confirmed.
- Not suitable for every window
- Opening condition affects secure fit
- Product-specific clearance still applies
Choose before production
Mount type changes the finished result.
Inside mount prioritizes a clean, built-in appearance. Outside mount can provide more overlap and usually reduces visible edge light, but it changes how the shade sits on the trim or wall.
For stronger room darkening, discuss outside-mount overlap, side channels, layered drapery or another light-management solution before the order is approved.
After installation
How we review a fit or workmanship concern.
A service review considers the confirmed order, mount type, product specification, opening condition, installation and operation—not one close-up photo by itself.
Product acceptance and limitation statement.
This section is intended to set reasonable expectations and support consistent after-sales decisions.
Custom window coverings are produced to the approved order details. By approving the product, mount type, control system, colour and measurements, the customer acknowledges that operational clearances, fabric deductions, light leakage, material behaviour and minor dimensional or visual variation may be inherent to the selected system.
Conditions that fall within the applicable SUNNY product standard or the product-specific specification are not considered manufacturing defects and, by themselves, do not require a remake, refund, replacement or free service visit.
Customer-supplied measurements: when products are made from dimensions supplied or approved by the customer or another third party, fit issues arising from incorrect dimensions, missing obstruction details, window changes or unsuitable mounting surfaces are not manufacturing defects.
Installation and use: damage or performance issues caused by unauthorized alteration, improper self-installation, failure to use supplied safety devices, misuse, impact, moisture, building movement or failure to follow care and operating instructions are assessed separately from manufacturing workmanship.
This guide explains general product expectations. The signed quotation, approved order, project-specific drawings, written warranty and applicable law take precedence where they differ. Nothing on this page limits rights that cannot legally be excluded.
Product standards FAQ
Questions about blind gaps and fit.
Why is the fabric narrower than the cassette or headrail?
The cassette contains brackets, end caps, a clutch, idler or motor. The fabric must be narrower so it can travel without scraping, fraying or binding. Fabric width and finished shade width are therefore different measurements.
Why is the gap larger on one side of my blind?
The control or motor side often needs more mechanical space than the idle side. Bracket placement, window squareness, trim and obstructions can also affect the visible reveal. Unequal side gaps are not automatically a defect.
Does room darkening mean the room will be completely black?
No. Room-darkening fabric significantly reduces incoming light, but an inside-mounted shade normally retains edge clearances. A near-blackout result may require outside-mount overlap, side channels, drapery or another solution specified before production.
Can the side gap be eliminated after installation?
An installer may be able to improve alignment or balance, but the engineered operating clearance cannot normally be removed. Making the fabric too wide can cause rubbing, tracking problems and damage.
Are the 1/4-inch, 7/8-inch, 3/8-inch and ±1/8-inch figures universal?
No. They are SUNNY reference points for a standard zebra-blind configuration. Roller shades, motorized systems, honeycomb shades, shutters and other products use different hardware and deductions. The confirmed order and product-specific standard govern.
What information should I send for a service review?
Send the order number, room and window identification, one full-window photo, close-ups of both sides and top, a clear tape-measure photo and a short operating video when movement or motor performance is involved.
How can I reduce visible light gaps before ordering?
Discuss an outside mount with added overlap, side channels, layered drapery or a different product type during consultation. These decisions affect measurements and must be made before production.
How are control-system safety requirements handled?
Cordless, wand, chain and motorized systems must follow the configuration stated on the order, supplied safety instructions and applicable Canadian requirements. Safety devices must not be removed, bypassed or altered.
Choose the right fit before we manufacture.
Book a free in-home consultation to compare mount types, light control, fabric deductions and operating systems for your windows.
