Well I finally decided to get my new headliner made up. I took a couple pictures is an attempt to help other people do it themselves. It's alot cheaper then the $200 some shops are asking!
First things first. You need to remove the headliner from the car. Take a sample of the old material into Autozone (which I did) and purchase the correct colour hedliner kit. Mine was grey. Can't really get that wrong.
At the same time, purchase headliner or fabric adhesive. The two can we had were made by Permatex and 3M. I don't know if other stuff works, but I know that these are two good companies and trust their supplies. You'll also need a sharp utility knife.
Step 1: Cleaning the cardboard headliner
The old adhesive needs to be removed from the headliner cardboard. You can use whatever you want to but we found that a large nailbrush was a very effective tool. We didn't get it clean enough to eat off, because we felt that scratching the remaining stuff off might damage the cardboard.
Step 2: Cutting the new material to size
Lay a clean sheet down on your workspace (we used a door screwed at one end to a bench and the other end supported by milk crates, then a large peice of plywood clamped to that, and covered it all in a clean sheet), and spread out the new headliner good side down. Place the cardboard on top and draw the approximate shape onto the headliner. Cut off the excess 6 or so inches from your draw lines. In my case I have a sunroof so I cut that out also. Take the cardboard off now and place it on the floor or somewhere you can spray the adhesive onto it.
Step 3: Spraying adhesive and attaching headliner
Take the can of adhesive and spray BOTH the headliner and the cardboard. Make sure you have the right side (duh). Spray the adhesive evenly. Don;t use too much on the headliner material or it might soak through when you press them together. Let them sit for 5 or so minutes (beer break...pop break..re-check the internet break). Now both pieces should be tacky to the touch. Lay a part of the headliner material onto the cardboard. Make sure you can see that your lines are lining up, and slowly press the material onto the cardboard. Don't use the points of your fingers or else the glue might soak through. Make sure you press the material into all corners and cracks and what not. Now you should have a headliner with excess material overhanging the edges and no holes cut for the lamp/sun-visors/etc.
Step 4: Trimming and attaching the sides
Once the headliner is nice and secure, flip it over and you should see the side that points to the roof. Trim the edges of the material so that an inch and half to two inches are remaining. Now spray the cardboard and material and let it sit for 5 minutes until it gets tacky. Make sure you spray the holes for the dome light etc etc. Now you should cut slices into all the curves so that you are pulling a peice straight up and it won't have a kink in it. See picture. Cut at the end of any straight peice, and the in the middle of the curves. Apply pressure and wrap the material onto the back of the headliner (both sides hve been sprayed).
Step 5: Replace in car
Here's the best part. Put it back in and admire what a cheap, quick and good job you've done. My car won't be put back together right away, but here's a shot that shows the great fit and finish.
Hope this page helped. If there are any suggestions/corrections please let me know.
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