The job was completed over 3 or 4 days.' i've got a few suggestions for anyone tackling this problem.

1. Keep a good recored of what parts you remove and where they came from. I had three paper bags marked "Rear", "Centre" & "Front". This made it easy to keep bits in order.
2. After removing the old roof liner from rotten foam from the roof shell, I'd recommend priming the shell with a latex primer or even brushed on contact cement. Either way, let it cure for a day before spraying it with the proper adhesive.
3. 3 yards of material and 3 tins of adhesive.
4. Spray at about 4" or 5 " from surface.
5. Test a small area for the right amount of adhesive on both the shell and the liner material.
6. Use a bit of careful heat to remove the drain lines from the drain pans. Blow air through the drain lines. Don't even think about not removing the drain pans to inspect. I found seed pods and all sorts of debris that would float into the pipe inlets. I also found that the pipe inlets that are "glued" into the pans had corners there the glue had shrunk. I'd never had seen any of this without removing the pans first.
7. Ditch all the Phillips screws and replace them with Robertson sheet metal screws. It's a lot easier to hold a Robertson on a driver in an upright position!
8. Take your time and think things through...
9. Not perfect but not bad.

 

What width of liner material did you get? I heard that you need extra wide material. Where did you get it? Thanks.

 

Hello. My Discovery 2 is a 2003 with dual sunroofs.

The fabric is 60 inches wide. That gave me margins of about 2” on either side of the front portion. 3 meters in length gave me a margin of about 12” at the rear side. A variant of colours are available.

I got the fabric from Christies Fabrics.

It’s called Headliner SunBrite Foam Backed Headliner Fabric. Shipped out of Richmond BC or Toronto ON. Very quick delivery.

I tried to add pictures but couldn’t for some reason.



I have ShopPro instructions for the headliner removal. I couldn’t add a PDF of those either.



Regards,

Peter Zdan

250-797-6352

 

This is my lucky day. They are located in Richmond and not far from where I live. The headliner project is something which I am planning to take on this spring or summer. Thanks for the info!