Roof Panels / Headlinging

[mikec]

Anybody have any wise words on putting in a new headlining? - We don't have the old one to use as a pattern.

Can / should we use 3mm / 6mm ply and cover it? We're hoping to get some of that foil/bubblewrap insulation up there too,so looking at a material/insulation/ply/insulation sandwich.

Any tricks to make sure it matches the curve of the roof? Thinking of screwing into the two chassis "hoops" and the front and rear box section.

Thanks as ever, Mike

[meehaja]

I've done the front section, but had the old headlining to draw around (and the metal rods) the rear is proving a bit harder, not least because once you get it to the right size, there is no where to tuck over hang that you can tension easily. I'm planning on using bamboo as the rods, as this is cheap, easy to cut and gives appropriate bend so it can follow the counters of the roof. I have foil bubble wrap stuff up at the moment and can suffer condensation at night (from breathing etc) so would avoid cardboard/ MDF due to mould risk?

There is a pattern in the wiki IIRC. I have seen a few people use velcro to attach it, but I'm not sure how secure that would be. Spray glue tends to unglue after a while (for me at least?)

Sorry I can't really help, but sharing my own problems might help you avoid the same pitfalls and it counts as therapy for me!

[boatbuilder]

I think this is the pattern you are referring to.
I'm planning to do this to mine some day when I ever get the bodywork done.
You can buy perforated vinyl on a roll and just cut it to length and sew in the loops for the support rods.
I managed to get an entire headliner including the rods out of an old caravelle. Headliner has lots of holes in it, but at least I can use it as a pattern for the new material.
I've put a new headliner into my Karmann Ghia before and the stuff to use is Evostik 528, you put it on with a brush. Spray glue IMO is not up to the job.

If you want a wooden headlining, you could use 4mm mdf, or you can buy special flexible plywood in 4mm sheets that would work well. I'd make sure to varnish or seal both sides of the wood before you fit it, or it could twist in the future.

[mikec]

Well, we took some 3mm ply from local supplier, much cheeper and better than B&Q, put foil/bubblewrap either side, topped it off with material and screwed it up with fat self-tappers and cup washers. Works "Good enough". only think got watch is cutting ply out around the side door slider.

Mike