OnyxCobra Posted July 20, 2012 Report Share Posted July 20, 2012 Just sharing my custom headliner project for those that might not have seen it. The stock cardboard one got creased up so I used it as a mold to make a fiberglass one. Overall I'm pretty happy with how it came out, it was my first time using fiberglass and also covering a headliner so I'm rather pleased.Supplies used not including the squeegee and paint brush:The stock headliner with all of the cloth removed:Then I laid the fiberglass cloth over the headliner and cut it into three equal sized sheets:Then I covered the cardboard headliner with foil otherwise the resin would harden to the cardboard and be impossible to remove:Then it was time to lay the fiberglass. First a layer of resin, then the first layer of cloth, then more resin, squeegee, next layer of cloth, etc. until you're done with the third layer. Squeegee proved important as it removed a lot of air bubbles and also removed all the excess resin.This is what excessive resin looks like:After the fiberglass is dry you're able to remove it from the cardboard mold. Peel off all the foil and trim to shape. It was important to test fit the fiberglass headliner in the car before cutting out the holes for everything because some of them were slightly different from the stock one.Here it is removed from the mold and cut out:Before I glued the suede down i sanded the whole headliner because the resin leaves a rather glossy finish and I wanted the glue to stick as good as possible. I found the gluing process very stressful as if I had gotten one crease I would have had to redo the whole thing lol. Unlike the stock cloth i wrapped the suede around pretty much every edge so that it wouldn't come hanging down in the future, here's the suede glued in place:All that was left was to put it in the car, while the dome light was out I put some LED bulbs in the dome and map lights, looks crisp. This is what I ended up with:Thanks for looking :cheers: Link to comment Share on other sites More sharing options...
330CubeGt Posted July 20, 2012 Report Share Posted July 20, 2012 Looks like you got your shit together for a first timer. Great work it came out real nice!Heads up and ass kickin! Using Tapatalk 2 Link to comment Share on other sites More sharing options...
Det_Riot Posted July 20, 2012 Report Share Posted July 20, 2012 DIY project of the year right here! Link to comment Share on other sites More sharing options...
OnyxCobra Posted July 20, 2012 Author Report Share Posted July 20, 2012 Looks like you got your shit together for a first timer. thanks I was rather impressed with how it came out, a little research definitely helps. Link to comment Share on other sites More sharing options...
Drake Posted July 20, 2012 Report Share Posted July 20, 2012 Wow :smile-new:.... how much for you to make mine. lol Link to comment Share on other sites More sharing options...
Bullitt Posted July 20, 2012 Report Share Posted July 20, 2012 wow that shit is hot!!! Link to comment Share on other sites More sharing options...
95opal Posted July 20, 2012 Report Share Posted July 20, 2012 Very nice onyx looks really good Link to comment Share on other sites More sharing options...
Tony Posted July 20, 2012 Report Share Posted July 20, 2012 ya already know i'm impressed! great job!! Link to comment Share on other sites More sharing options...
Ferocious Posted July 20, 2012 Report Share Posted July 20, 2012 Sometimes I wish I had a roof... Link to comment Share on other sites More sharing options...
iRoush Posted July 20, 2012 Report Share Posted July 20, 2012 Sometimes I wish I had a roof...I personally couldn't live without one. looks great Onyx! Link to comment Share on other sites More sharing options...
OnyxCobra Posted July 21, 2012 Author Report Share Posted July 21, 2012 Thanks for the kind words guys.Wow :smile-new:.... how much for you to make mine. lolI have a feeling the price I'd want to charge would be more than most would be willing to pay. It was time consuming and messy, it was fun for the most part but I'm glad I don't have to do it again. Link to comment Share on other sites More sharing options...
Jeremy95GT Posted July 21, 2012 Report Share Posted July 21, 2012 That's a Damn pro job right thurr... Looks awesome budSent from my EVO 3D using tapatalk Link to comment Share on other sites More sharing options...
Number Tew Posted July 21, 2012 Report Share Posted July 21, 2012 Really guys it's not that hard to do. Use this writeup, it's great. Pull a liner from a junk yard so you don't risk ruining yours, and glass away. Like I told onyx before, I'd use a roller and 1.5oz mat instead of a regular material, but that's just me. Still love how it came out. Link to comment Share on other sites More sharing options...
Steve Posted July 21, 2012 Report Share Posted July 21, 2012 Look great nice job and writeupive wanted to do mine for years since I quit smoking like 2-3 years after I for my 00 and just want all traces gone even though I steamed it. My plan is to go with matching parchment vinyl/leather for a smooth finish. Link to comment Share on other sites More sharing options...
OnyxCobra Posted July 21, 2012 Author Report Share Posted July 21, 2012 I actually found the brush to be a lot better than the roller. The roller pulled the foil up a lot when laying down the first coat of resin and also laid down way too much resin, the brush made it easy to apply resin and was more controllable as well. Squeegeeing the excess resin off was key for removing excess resin so it hardened/dried more quickly and also to remove the larger pockets of air.Leather would look cool also if you wanted a smooth look, I was all about the suede. Link to comment Share on other sites More sharing options...
Drake Posted July 21, 2012 Report Share Posted July 21, 2012 I feel ya on that looks so good, anyways why did you have to make the fiberglass couldnt you just apply it to the cardboard? Link to comment Share on other sites More sharing options...
Alscobra Posted July 21, 2012 Report Share Posted July 21, 2012 (edited) I feel ya on that looks so good, anyways why did you have to make the fiberglass couldnt you just apply it to the cardboard?Was kinda wondering that myself. I've done headliners before. You can buy replacement foam backing and 3M spray adhesive is all I ever needed. Dunno. Looks fantastic though. Edited July 21, 2012 by Alscobra Link to comment Share on other sites More sharing options...
dutch Posted July 21, 2012 Report Share Posted July 21, 2012 That´s awesome Ryan! Link to comment Share on other sites More sharing options...
Number Tew Posted July 21, 2012 Report Share Posted July 21, 2012 Was kinda wondering that myself. I've done headliners before. You can buy replacement foam backing and 3M spray adhesive is all I ever needed. Dunno. Looks fantastic though.He did it to make sure there would be no wrinkles or creases from the bends in the cardboard.Onyx, rolling takes some practice, I used to hate running a roller and always preferred a brush, until I knew how to do it. But rollers are designed for mats and not material like you were using haha. So for what you had, yes a brush was better We are agreeing, just going about it different ways.I still love this, so much.I'll probably do vinyl though because I'm a total vagina and I'd ruin the suede. Link to comment Share on other sites More sharing options...
OnyxCobra Posted July 21, 2012 Author Report Share Posted July 21, 2012 why did you have to make the fiberglass couldnt you just apply it to the cardboard?yeah as mentioned the stock cardboard headliner had quite a few creases in it from removing it and I didn't want to chance them showing through the suede. Also there were even some parts where the cardboard was separating from itself and I didn't want to go through all the work just for it to look crappy afterwards. Is there a chance I could have covered the cardboard one and had good results, sure.He did it to make sure there would be no wrinkles or creases from the bends in the cardboard.Onyx, rolling takes some practice, I used to hate running a roller and always preferred a brush, until I knew how to do it. But rollers are designed for mats and not material like you were using haha. So for what you had, yes a brush was better We are agreeing, just going about it different ways.I still love this, so much.I'll probably do vinyl though because I'm a total vagina and I'd ruin the suede.I get what you're saying. Are you talking about a roller to apply the resin or a roller to squeegee the air bubbles out? I did look at that fiberglass mat stuff, looked like it could be a mess. Also I explained to the guy at US Composites what I was going to be doing and he recommended the fiberglass material that I purchased. He's the one that also suggested three layers, very helpful place to buy from.After looking at tons of Lambos, Ferraris, Bentleys, etc and seeing nothing but suede in their interiors I was like I need to have some of this stuff in my Cobra lol. Link to comment Share on other sites More sharing options...
ttocs Posted July 21, 2012 Report Share Posted July 21, 2012 I started to pull mine out last night. I say started because I am amazed at how well you can bond cardboard to metal and have it hold for 18 yrs.... I was wedging my hand/arm between the roof/cover till I saw how bad it was flexing the roof. No joke I was afraid the paint was going to seperate. I am going to try it again in a few and stick a hair dryer up there to see if some heat will help it seperate, if so I would be able to use it to secure it again which would be nice. My mother is a sewing wiz. I was going to have her make covers for the visors and could probably have her make an extra set if you have any left over material. Link to comment Share on other sites More sharing options...
OnyxCobra Posted July 21, 2012 Author Report Share Posted July 21, 2012 That's what I'm saying man, Ford used an insane amount of glue to hold it in place, they really didn't want it coming down ever. I used my hand too but could only get it so far, then the creases started and once that happened I said F it lol. Hmmm I never thought about covers, that isn't a bad idea. i do have a ton of left over material. could you give me an idea of how it would look? Link to comment Share on other sites More sharing options...
ttocs Posted July 21, 2012 Report Share Posted July 21, 2012 see thats the funny thing the dome light in the middle will hold it just as well as their 20lb of 1000lb-hold glue. As for how it would look while she has never done visors before I have seen her reapolster(SP?) our couch 2 different times to the point you could not tell. The visors are a pretty simple design for the cover, I already tore the drivers side off to install the monitor. its just 2 pieces of cardboard with a wide slit inbetween them that the seem gets tucked into. I didn't pay attention to how the mirror was attached as I was cutting it out is my only question. we can cross that bridge when we get there. Hopefully I will get mine out today/tomorrow... Just gonna turn on a hair dryer and stick it up inbetween the two. Should hold the heat inbetween the two, as well as provide some light weight to pull it down slowly. Hell I hope this works or else I am gonna get out some kind of power tool, I know an angle grinder will take it out...... Link to comment Share on other sites More sharing options...
OnyxCobra Posted July 21, 2012 Author Report Share Posted July 21, 2012 angle grinder lol. Yeah if your mom is doing yours i'm definitely interested to see how they come out.You'd be right about the dome light if it mounted to the roof of the car but it doesn't, it just floats in the headliner. Otherwise no they probably wouldn't have needed much if any glue. Link to comment Share on other sites More sharing options...
Number Tew Posted July 21, 2012 Report Share Posted July 21, 2012 I get what you're saying. Are you talking about a roller to apply the resin or a roller to squeegee the air bubbles out? I did look at that fiberglass mat stuff, looked like it could be a mess. Also I explained to the guy at US Composites what I was going to be doing and he recommended the fiberglass material that I purchased. He's the one that also suggested three layers, very helpful place to buy from.When I have to glass without a chop gun (chop is basically that mat I'm talking about that comes out of a gun in little strands already mixed with resin and catalyst) I get resin mixed up in a bucket, lightly brush the surface of whateverr I'm glassing to, put material on it, then either brush resin in (small project) or get to dumping it (lot of space to cover with not much time to work haha) and use a roller, to roll out all the bubbles and spread the resin evenly. There's a few kinds of rollers, paddle rollers, bubble busters, different handles, etc. I've worked with all of em lol. As far as the company, most composite places have excellent customer service. For a while I was the material specialist in the yacht building at regal so I got to deal with lots of vendors. No complaints from any of them really.I still love this project, and I'm glad it worked out for you. Link to comment Share on other sites More sharing options...
ttocs Posted July 21, 2012 Report Share Posted July 21, 2012 myself in my projects with glass I have used nothin more then bondo brand from home depot and never had an issue.Heat did little to nothing to it I am sure that ford has reverse-engineered some form of alien technology that now allows them to weld carpeted pieces of cardboard to metal. Not sure how they do it but they do it.... Link to comment Share on other sites More sharing options...
Number Tew Posted July 21, 2012 Report Share Posted July 21, 2012 It's Hencho in Mexico, that's how. Link to comment Share on other sites More sharing options...
OnyxCobra Posted July 22, 2012 Author Report Share Posted July 22, 2012 Yeah they really did use a ridiculous amount of glue.The first roller i tried to use was a paint roller, it just applied way too much resin and also did nothing to get air out. If any roller was going to be used it would have to be one of those hard rubber rollers but it was more than i wanted to spend. I actually got a lot of air bubbles out by using my hand in the tighter and more curved areas.I noticed the headliner is hanging down just a bit in certain areas because I didn't use any glue to reinstall it, i may try to hold it up in a few places with some Velcro, just something to offer support but it's not permanent in case I want to remove it in the future. Link to comment Share on other sites More sharing options...
Number Tew Posted July 22, 2012 Report Share Posted July 22, 2012 I thought you meant it was drooping off of your glass, but now I understand lol! Phew!And hey, who cares what you did to do it, you got it done, and it works, and you're happy and it looks Damn good! Link to comment Share on other sites More sharing options...
Steve Posted July 22, 2012 Report Share Posted July 22, 2012 FYI if you ever need a small, hard roller. Lowes, Home Depot, etc look for floor edge molding it's rubber comes in 50 ft rolls and by the tools for it they'll usually have a 3" hard plastic roller that is great for getting bubbles out.Sent from my iPad using Magic. Link to comment Share on other sites More sharing options...
ttocs Posted July 22, 2012 Report Share Posted July 22, 2012 ace hardware sells theirs in the wallpaper accesories area.Finally got my headliner out. Missing some skin on the top of m fingers from it but managed to do it with out screwing up the cardboard so I can just re-use it. Mine will be made a little harder as I am also installing an explorer overhead consol and my headliner has a 1" green stripe in the middle of it like my custom leather boots. Link to comment Share on other sites More sharing options...
Silverv6 Posted July 22, 2012 Report Share Posted July 22, 2012 That looks awesome onyx! Link to comment Share on other sites More sharing options...
OnyxCobra Posted July 23, 2012 Author Report Share Posted July 23, 2012 I actually did check Home Depot but the only hard rollers the guy could find for me was a little spendy and larger than I wanted. The squeegee was really cheap and did a great job, I'd use it again.ttocs, patience is the name of the game for removing the stock one and unfortunately I just tried to rush mine, oh well. good luck with that overhead console, I hope it mounts more straight forward than the net pocket I was going to use. Link to comment Share on other sites More sharing options...
OnyxCobra Posted July 23, 2012 Author Report Share Posted July 23, 2012 I thought you meant it was drooping off of your glass, but now I understand lol! Phew!lol yeah no the suede is stuck down really well to the glass, the glass just isn't stuck to the roof. OMG if the suede started sagging already I would lose it lol.and thanks everyone. Link to comment Share on other sites More sharing options...
Number Tew Posted July 23, 2012 Report Share Posted July 23, 2012 lol yeah no the suede is stuck down really well to the glass, the glass just isn't stuck to the roof. OMG if the suede started sagging already I would lose it lol.and thanks everyone.Scared me for a minute haha!I need to meet so many peoples cars haha. yours is on the list ;p Link to comment Share on other sites More sharing options...
OnyxCobra Posted July 25, 2012 Author Report Share Posted July 25, 2012 i do wish I was closer to a lot of you guys, it would be really cool to be able to meet up and cruise. Link to comment Share on other sites More sharing options...
ttocs Posted July 25, 2012 Report Share Posted July 25, 2012 i was looking at the visor this morning while I was working on my headliner and there isn't even any sewing that would need to be done to cover them. If you look at the edges you will see that it is just a single piece of fabric that the press between two pieces of cardboard. The hardest part would be just tucking it under the plastic pieces but I think with a small flat-head and some patients it would not be that bad. Link to comment Share on other sites More sharing options...
Coupe_5ohh Posted July 25, 2012 Report Share Posted July 25, 2012 and glue...lots and lots of glue Link to comment Share on other sites More sharing options...
OnyxCobra Posted July 31, 2012 Author Report Share Posted July 31, 2012 i was looking at the visor this morning while I was working on my headliner and there isn't even any sewing that would need to be done to cover them. If you look at the edges you will see that it is just a single piece of fabric that the press between two pieces of cardboard. The hardest part would be just tucking it under the plastic pieces but I think with a small flat-head and some patients it would not be that bad.having trouble visualizing this... would it be one piece that I'd have to slide over? What would close it up to finish the open end off, and would it still clip into place, etc? Link to comment Share on other sites More sharing options...
ttocs Posted July 31, 2012 Report Share Posted July 31, 2012 I know, its hard to explain.... it would be one piece, wrapped around the end that has the mounts on it and tucked in between the two pieces of cardboard on the other end(closer to your face). Next time you are in the car look at the end and you will see what I mean that the end with out the mounts will have two edges where it is tucked into the seam between the cardboard. Little bit of glue on the material in the middle to start it out on the edge with the mounts and work your way to one edge. When you get to the end, cut it 1/2" longer then the edge, a little bit of glue on the material and then tuck it between the two edges. Now work on the other side again down to the edge. You would need to cut it around the mirrors and tuck it under the plastic but no big deal there really. Now again when you get to the end cut the material 1/2 longer then you need it but this time don't glue it and still tuck it just like the other. Don't glue the 2nd edge to keep from getting the glue on the first edges new material. Instead to hold it in place take a 12-14 awg piece of wire and put a little glue just on one end, now tuck that between the two edges and then put some glue on the other end to hold it in place. Link to comment Share on other sites More sharing options...
