I’ve had the headliner out of my truck for literally months working on a sunroof leak and I’m finally at the point where I’m going to redo the headliner and reinstall it. While at work i ordered the material that I want as well as some 3/16 headliner foam. When I got back home though it appears that the headliner is 2 fiberglass pieces sandwiched around a layer of foam with a layer of degrading orange foam attached to the fabric. Are folks just scraping off the exterior layer of crumbling orange foam and then applying the new fabric directly to the fiberglass or should I put down my new headliner foam and then apply my fabric? Will that make my headliner “too thick?” Thanks for any advice. I’m all for functional and rugged but I’ve had enough of driving around with exposed wires dangling down!

 

I got rid of old crumbly foam stuff using a wire brush. Then painted mine. I don't think you need to apply new foam. I would just adhesive the headliner fabric to the headliner fiber board. Here are a couple of videos showing straight adhesion to the fiber board itself.

You may also want to consider sound deadening material, eg, Dynamat.

 

I tried DIY once, made a mess of it, $60 in material and it looked like ***. My local upholstery guy does it for $80 when I bring him the board. I would recommend painting the top of the board with stain blocking paint. Put a bead of silicone around every penetration so any water that makes it on to the board does not get to the fabric.

 

I rolled mine with Rust-Oleum bed liner, single stage. Same stuff I roll my yota tube front/rear bumpers and sliders. Pretty durable and when crap happens like your kid tossing in a fishing pole with zero regard for the headliner, easy to touch up.

 

No need to replace the crumbling foam. The replacement liner fabric already is thick.

If you do go with proper headliner fabric, DO NOT do it solo like I did. It’s definitely a two person job and you want to go super slow. Or hire a pro.

 

The crumbling foam is the foam backing that’s part of your headliner fabric. Your new headliner fabric should come with foam backing. Yes you need to scrape off the old foam. You use spray glue to install the new fabric. I did do mine (on my P38) by myself. I agree that two people would have made it easier but I’m stubborn. It didn’t turn out too bad. Not perfect but I think I’m the only one who can notice any errors, and then only when I look for them.

 

Pull the board, and find a small but reputable upholstery shop. Local place did mine for a couple of hundred and did a beautiful job. While it was out, I redid the sunroof seals and drains and cleaned and lubed the sunroof mechanisms. Both work great now and no leaks!!

 

scrape off the old foam with a cheap wire brush for a bbq. the new materials won't stick very well if you don't.

I'd also put some stick on heat shield material on the inside of the metal roof.

 

I second what a few have said here. I did it myself, wasnt upset with the results. One or two spots that i kick myself about when i look at them. My number 1 tip, pay close attention to the bit that folds under right at the windshield, thats what you look at most of the time. Lots of posts on which spray glue etc. Think I tested 3m and some specific headliner glue. I preferred the 3m as it was slightly reposition-able, like once.

Scrape old foam with wire brush. New foam/material will hide any little bits you dont get. Yes, get some hushmat/dynomat, and stick to exposed roof panels. I then used some padded silver insulation in addition. The biggest win from my headliner job is the increased sound and temp insulation. Makes the drive far more comfortable.

Good luck.

 

This stuff isn't cheap, but it works really well for the backside of the headliner....made a big difference on my interior temps on my old D2 (wrecked) in the Texas summer heat. Just be careful about installing it too close to openings (into the cab aka lights, grab handles, ducts etc.) and to the edges (especially the front windshield area...I think I used a thinner one 1/4" maybe) or you might have issues with fitment going back in. you can use metal/foil tape to "seam' the rows/pieces together.