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5.5 - Replacing Headliner ( )

You will find that there are thin foam backings and thick foam backings.

First step is removal of all the plastic trim pieces that hold the cardboard headboard.

Next remove the old stuff. This will be a mess, old decomposed foam everywhere.

Third get the backing out of the car into the garage/ workshop. You may want to consider removing the rear windscreen for this because to get it out the back door you will have to make what looks like a rather uncomfortable bend. This mildly crimps/kinks the cardboard, but the (new) foam of the headliner will easily hide the cracks.

Sand and vacuum every last speck of old foam off the headliner. For the sun roof, remove any foam/old glue. Glue on the new headliner as per the adhesive instructions. Avoid stretching the material as much as possible.

Trim the excess material from the edges. For the sunroof hole, leave a good 3 inches (7cm) of slack (you can always take off more later). For the switch panel there are 4 little 'clips' that fit on plastic posts. These may be destroyed when you remove them, but zip nuts (they're little plates of spring metal with a hole in the middle designed to be, well, nuts - as in what a bolt goes into) make a perfect replacement.

You will need about nine feet of material. You need the length of the headliner board, plus the length of the sunroof plus an extra foot/ 30cm for 'insurance'. There was no bead or rope on the edge as it is hidden by plastic trim.


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