So far, on every resource I can find, all headliner replacement parts/tutorials/etc focus solely on the fabric and assume the board itself is ok. My 1996 Discovery has a sagging headliner board and fabric. I've found one full board on eBay but it's $275 plus an astronomical shipping amount, and I'm at a loss for what to do. Looking for alternative sources for a replacement board and/or DIY solutions.

I'm new to the board with more than one item I'm stumped on. This is my first one.

 

A good way to stiffen up these boards overall is to use PVA glue (wood glue) watered down about 2 parts water 1 part glue. Apply it to both sides generously - I use one of those cheap foam paintbrushes. Let it take up what it can soak up on one side, let it dry and then do the other.

Goes without saying you should do a good job cleaning the board first of all old headliner materials, etc. and that you need to support this thing on a table in the shape it needs to be in at the end, because that glue is going to stiffen it up a lot.

 

Junk yard. Headliner boards go for about $40.00 at junkyards. Plus, since you are up in there you can grab the sunroofs with the motors for about $65.00 each, then sell them on eBay for about $325.00 - ask me how I know that!

 

Would my local Euro mechanic have leads on junkyards? I don't mind the idea of taking the whole thing down and stiffening it up though.

 

I suspect someone re-installed yours without putting the screw behind the rear sunroof button on it. That attaches the middle of the fiber board to the metal roof.

 

That's a good way to destroy the board pretty quick.

 

I probably didn't describe it well enough. There is a plastic piece that is attached to the fiber board which accepts the rear sunroof switch. Pull that switch and you will see how the plastic behind the switch is designed to be screwed to the metal roof. This is close to the central point of the board and will support the board. I circled it in the picture.

The other thing to check is the weather strip around the opening of the sunroofs. That strip which as grey fabric on it to match the which covers the rough edge of the board has a cross section in the shape of an E. The bottom of the E covers the edge of the board, the top section slides onto the metal of the sunroof tray. This strip is important in attaching board to the roof.

 

Now that's looking like what might be missing, because the sag is where all this stuff is located. I will investigate further around this plastic. Thank you!

 

My headliner is still out on the D1. Let me know if you need pictures of things as you go along.

 

the second picture in this thread is quite clear. Pull the switch to find the mounting point where a screw holds the headliner to the roof.

https://discoweb.org/index.php?threa...astics.101254/