Headliner Removal

[grizzlygibbs]

Found small specks of rust around the nutserts when I removed the factory rack this afternoon. This all came about by me removing my tail fin because it interfered with loading the kayak (Jackson Big Tuna) on the factory rack I noticed slight rust. around the nutserts.

The nutserts did not spin but they spun when I tried drilling them out. Gonna take a grinder to them in the morning and I am gonna have my brother-in-law weld the holes up.

The headliner was not a headache to remove at all, just took some time. The one piece unit was nice and easy to remove. Going to lightly clean it and shoot it some with frebreeze before I pick up some reflectix and put everything back together.

Most time consuming of it all is getting all the hardware out. Looking forward to getting this knocked off the bucket list. Crappy iphone pictures to come.

I got some Thule gutter mounts and took the top rack and ribs off the top today. Going to get some walmart speakers for the far back seats as well.

 

[grizzlygibbs]

Headliner removal

• grizzlygibbs
• Oct 15, 2015

Headliner

• grizzlygibbs
• Oct 15, 2015

Removing the headliner.

 

[grizzlygibbs]

Now, do most guys revive the factory insulation as well?

I plan to use a sound deadened if I can find some cheap stuff at Home Depot and reflector as well.

 

[Luke111]

Now, do most guys revive the factory insulation as well?

I plan to use a sound deadened if I can find some cheap stuff at Home Depot and reflector as well.

I used a wire wheel on a drill and removed the insulation and used a sound deadener... and also used a heat gun and peeled the fuzzy head liner material right off the fiber board and glued down marine vinyl for a big change to the interior .. Marine vinyl is dirt cheap to buy.

Lou

 

[Luke111]

I few pic and the best glue to use ...the best contact glues are flammable you won't find this in any of the big box stores. I purchased this locally at a carpet installation supply company recommended by a Porsche restoration shop ..

 

[Geert]

That looks doable indeed... but I have the old style headliner . I only removed the rear and then I realised removing this is one thing, but reïnstalling is another...
So for who is interested:
Removing the old style headliner is a PITA... so just leave it
We decided to just pull the nutserts out. If you put a bolt in there and a vise grip you can wiggle them loose.
Then you make small rectangular pieces of steel that you put in the hole. Weld a big pointy piece on the small rectangular pieces so you can hold it in there. You then flatten the steel of your roof around the hole (it bends a little outward because you pull the nutsert out). Then you take a TIG welder and weld the holes. Then you can break the big piece off the small rectangular plate. A MIG welder makes to much sparks and is very dangerous for your headliner to catch fire! Welding with the TIG didn't make any spark. Just don't weld too long in one time, just for the heat.
I had a different type of roof rails (guess European thing maybe) I wanted it gone, because the roof rack doensn't fit above the rails and there was some rust around the nutserts.

Pictures:

The roof is repainted now and it looks good

 

[grizzlygibbs]

I used a wire wheel on a drill and removed the insulation and used a sound deadener... and also used a heat gun and peeled the fuzzy head liner material right off the fiber board and glued down marine vinyl for a big change to the interior .. Marine vinyl is dirt cheap to buy.

Lou

Luke, that sounds very messy. I guess I need to buck up and put on my respirator, goggles, and tyvek suit. I am going to see if there is any kind of over the counter sound deadener at Home Depot.

 

[Luke111]

You have no idea it went everywhere . The stuff that didn't come off got burnished into the glue...good enough for the the sound deadener to stick

 

[grizzlygibbs]

You have no idea it went everywhere . The stuff that didn't come off got burnished into the glue...good enough for the the sound deadener to stick

Hmmm, not sure I want to do that. I wonder if I could burn it off...

 

[Luke111]

I had pulled everything out so it wasn't hard to clean up and it went really quick ..Burning is an option but could be pretty toxic

 

[grizzlygibbs]

The welds look horrific. Ha ha. But I think it is adequate.

I am getting ready to grind them down a bit and primer it. Only had a small fire and a couple of sparks that fell on the carpet. I forgot my moving blankets at home and already got to the my brother in laws.

I dropped the rear 5 bolts of the sunroof to access the front holes with my slag catch can. We took a piece of rubber weatherstrip around the top of a cut down coffee can with a bit of water to catch the Sparks.

I kept asking if the welder was set too hot....

Some of the insulation I peeled back did catch fire so beware to all those who attempt to weld without dropping headliner and remove the insulation.

 

[grizzlygibbs]

And here is the undercoating I found at Home Depot. Rustoleum Rubber Undercoating. Supposed to be ok stuff. At least provides a little bit. I put 3 coats under the sunroof pan.

Going to add reflectix under the headliner as well. Going to wait a couple days for the smell of spray paint to go away. I am ready for another number 6.

 

[grizzlygibbs]

I ground down the welds before it got too dark. A couple need to be filled a little more.

Bro-in-law says its because there was a slight breeze...

The welded holes overall look pretty good ground down, just one or two very tiny pin holes left.

He said he had the welder on the lowest setting. Not sure if this was a factor or not, I have never welded before. All I knew is sparks flew everywhere and tonight I noticed a couple specks in the rear hatch glass where the sparks burned the glass... He said that should not have happened either. I was a little pissed about that part. He has done good work on projects that do not need to be water tight and he is not exactly a perfectionist but this will work out I am sure, especially now that there are not big holes in the roof, just small almost microscopic ones.

I still have to get the ribbed tracks off the roof as well. I am going to try the towel and ironing method.

I will be happy when this is done and at least primed. My Monstaliner for the roof is waiting patiently in the garage.

 

[Geert]

We tested the welds by blowing on them with an air compressor. When the headliner moves, it's not good.