I have a 83 Camaro Z28 that I am working on. The headliner material was sagging and coming off the foam back board. The foam board was also in sad shape. While numerous companies make aftermarket headliners, these all are out of my budget.

I visited my local salvage yard and found a headliner that was sagging but the foam board was in descent shape. I was able to pick this up for almost nothing, since the salvage yard considered it useless and of no real value. I think I paid $2.00 for it. Once I got it home, I pulled off the old material and cleaned the foam up as best as I could.

I then used a quart of fiberglass resin, hardener I had and a set of cheap paint brushed from the local dollar store. I coated the foam board several times with the fiberglass resin until the foam board became rigid. This process took several days and multiple coatings of the fiberglass resin. I used the fiberglass matting were the foam board was cracked or weak. Once I was happy with the rigidity of the board, I sanded it smooth with some 80 grit sandpaper. This also gives the board some roughness for adhesive to grab to.

I went to Jo Ann Fabrics and found gray headliner material, which matches my interior color,. I purchased 2 yards and then stopped at Home Depot and bought a quart of latex construction adhesive. Using a 4” wide body filler spreader, which I cut notches into, I spread the adhesive onto the headliner board. Once completely covered, I put my headliner material down and used a small lightweight roller I made to even out the material.

I put this aside and let the adhesive completely dry for several days before. I have pulled on the headliner material and it is completely adhered to the board. All I have to do is some trimming and replace some broken clips and I have a new headliner.

Costs:
Old Headliner - $2.00
Adhesive - $7.95
Headliner Material – 14.95 a yard x 2 yards = 29.90
2 packs cheap paint brushes – $2.00
Fiberglass resin and hardener – had on hand

 

pics would have bean good to go along in your posting

 

I agree - pics would be nice...

 

Sorry I did not post pictures before, I had to go back and search my camera and computer to see if I took any when I did the project. I was able to find some pictures from the project.

Head Liner Before is the condition of the headliner board when I got it home from the salvage yard.

Headliner 1 is after I coated it numerous times with the fiberglass resin. The resin darkened the color of the board. This is the underside (against the roof) of the board.

Headliner 6 is the covered headliner board.

 

Some more of the headliner project pictures.

Headliner glued is the edge of the liner board when I glued it

Head Liner 2 Before is the condition of one of the edges that surround the seatbelt mechanism

Headliner 2 is the same area after i fiberglassed and used the matting to repair and strengthen

I hope these help

 

I'm in the process of doing the exact same thing! Glad to see your pics, now I know what I'm doing will actually work, thanks!

 

Hey tbroadfoot125 - thanks for posting the pics!

 

Thats a neat Idea! One question, Does the headliner need to be "flexed" at all to get inside the car? I would be worried it may crack or something. I've never had a headliner out before, and I may need to do it shortly, so I was just wondering.

 

thanks for putting up pics, How well did the fiber board soak up the resin ? Did it seam like it when all the way threw ?