Figured what rattled everytime I shut the door. It was the overhead rear brake light assembly that had become unglued from the headliner. Put some glue and riveted it for good measure.

 

Can't wait to to see the finished product, what are you wrapping it in? Suede?

P.S Mods should add this to the How-to sticky links.

 

P.S Mods should add this to the How-to sticky links.

Tom is MIA.

 

Nice writeup!

I know how ya feel about removing the headliner once it isn't attached. It was super frustrating getting it out and took a while.
Excited to see the finished result.

 

Thanks guys.
Hey carreragt7 did you also remove the sliding sun shade? I couldn't figure out how to take that out....

I'm going OEM, so it'll just be another gray colored headliner. I have a off-black and gray interior so I can't get too crazy.

 

Let's just say I'm not much help there. It took me like 4 hours to get it out, and 6+ to get it back in and it doesn't slide properly. I don't use my sunroof that much so it doesn't bother me.

What really sucks is I used a different adhesive on the sunroof cover because I ran out of the other adhesive, and it failed literally 2-3 days later. So the middle piece of my sunroof doesn't have material on it and looks bad.Whenever people ride in my car I just open the sunroof, lol.
For all the work you've done you should mix it up a bit, but an OEM-like headliner material would be the simplest/best material to use since it is made to be lightweight and last.

 

Oh okay, lol. I started a new post asking for help so I'll just wait.

I thought of using leather, but what I paid for the cloth material ($45) is about the max I'm willing to spend on it.

 

I drove without my headliner in for like 3 weeks, lol.
I know how that is with pot holes, on my way back from Seattle a few weeks back I blew out a tire. $800 later and I've got new tires...

 

damn!
the worst thing was, I drove over the pothole with both the front and rear wheels, as if once wasn't enough. I thought I should just turn around and drive through it again with my other two tires to even it out.

 

That's it for tonight folks. Hope these photos are archived in swedespeed servers.

Thanks! The thread has been linked in the sticky. As for the photos, no they are not archived in the SS servers. That function did become available with the new forum software, but for some reason it doesn't work and the admins haven't indicated it will be enabled. If you plan to take the links down, please advise as it will break the post.

 

Will do Tom. I was concerned because I have so many pictures taken for the write ups I did, and they are hosted in two different online photo sites. I may not remember which photos should not be deleted when the time comes to clean up my accounts.

 

1. Before starting the adhesive procedure, fold the headliner in half all the way length-wise. Then use tacks to hold it down in the center while you measure to see if you have enough material to go to the edges. I was concerned because my material is only 54 inches wide and cutting it real close. The rear of the headliner requires the most fabric so start there. Despite doing this, I came up a little short on the rear corner.

2. Start spraying the adhesive and work on small sections. Don't get too ambitious because the glue is extremely strong and working the material into the depressions and compound curves takes a lot of finesse. I messed up in a few spots around where the grab handles are. You can see creases from my amateurish effort.

3. Do not precut the material to the exact size yet because you may want extra material to fold over the edges. That way it would be a little more difficult for the headliner material to start unraveling and fraying at the edges in the course of time. Additionally, I don't like being able to see the sponge backing through the front windshield glass if you cut it right along the edges.

4. Once you have finished with the entire liner, flip it around and leave about 1.5 inches beyond the edges and cut around the headliner. Then spray the glue and fold over.

5. Let it stand to dry before cutting out the holes.

 

2. Start spraying the adhesive and work on small sections. Don't get too ambitious because the glue is extremely strong and working the material into the depressions and compound curves take a lot of finesse. I messed up in a few spots around where the grab handles are. You can see creases from my amateur effort.

+15697813. When I was doing my headliner it was a freakin' nightmare. Let's just say I was a bit over zealous when it came to spraying adhesive.

 

The sliding sun shade needs to be removed in order to reupholster it. (thank you Kyle for the instructions)

The sunroof glass has to be removed. Hopefully at this juncture, you have the sunroof completely closed. Otherwise you may need to reconnect the battery and close the sunroof glass.

1. There are two T20 bolts on each side of the sunroof glass. The accordion privacy louvers need to come off. Remove by pulling them at their anchor points. Do not yank anywhere else or you may tear it like I did.

2. Once off, you can see the two T20 bolts. Unscrew them all while supporting the glass.

3. Take the glass off from the top and set it down someplace where you won't step on it.

4. Pull the sunshade forward and look through the top. There are a total of 4 T20 screws that hold it on the track. Unscrew the front two.

5. Then take the track guides off so you don't lose it.

6. Pull the shade forward some more to access the rear bolts.

7. The shade comes completely off. No hacksawing required!

8. The plastic piece comes off by pushing all of these tabs. Then the entire liner can be ripped off right down to the metal backing plate.

 

When upholstering the sun shade, leave extra fabric at the edges to fold over, just like the headliner. Cut a narrow strip out from the middle of the ventilation holes. Do not cut to the edge otherwise you will see ugly edges of your headliner material peeking out from under the plastic piece.

I also found it advantageous to leave some extra material around cutouts so they act as vibration dampeners. The clips also hold a little more securely.

Back and front after cutting out the sunroof hole

The finished result, a factory look.
Before:

After:

When light hits it a certain way, the headliner looks lumpy, but I'm very happy with the result and the amount of money I spent on this project.

Total Cost:
$48 for 3 yards of headliner fabric at Jo-Ann's
$12 for 2 cans of headliner adhesive spray at AutoZone
$0 for lots of elbow grease

Dealership estimate: $900
Upholstery shop: $300-$400

Peace of mind knowing it was done right and all pieces/screws are in place: Priceless!

_____The End____

 

Just in case you've ripped the privacy panels and want to replace the straps, here are the part numbers:

Modesty Panels : 30799289-1 $21.59
Clip (Strap) : 30781445 $3.81

 

Sorry to bring back such an old thread. I just wanted to say, when removing the A-pillars, you don't have to cut the retaining straps. They slide in/out of the A-pillar panel. It's a paint to get them back in, but a peace of mind knowing that the panel won't fly across the car in case of airbag deployment. I can post a picture of what I'm talking about later.

 

Here's how you can easily unhook the retaining straps to the A-pillars, so that they can be reattached later.

No worries of panels flying about the cabin upon airbag deployment

 

thanks MyNameIdeasWereTaken for bumping a old thread lol & thanks aldebaran for the d.i.y. have to fix my falling sunshade

 

I followed this procedure yesterday and it was pretty difficult to get the headliner out without bending it.

I'm not sure if after putting a new foam and fabric the few bends I made will no be visible, there are 2 lines ( like if it broke ) on the foam/fiberglass.

I also scratched a bit the waterfall console. It would have helped to put the car on D before unplugging the batter as well.

For putting it back in, I'm removing the console. I'm pretty sure that it will come in without having to bend it if I do so.

http://forums.swedespeed.com/showthread.php?167046-How-to-Videos

 

Yeah, shift nob in a downward position really helps. Never thought about removing the console, but that would probably make this job effortless then!

 

After some Spring Storm - I'm getting more E-mail about this Issue : Sticky Area for some Reason seems Hard to locate to some .

___Photobucket has Limited the Amount of Information - Clearly to be Displayed - No Description Area Currently as Before .

______( FELL FREE to Write Me as many Others have and get Needed Details on Fixing )

http://s261.photobucket.com/user/EngTech1/slideshow/Sunroof%20%20Maintenance%20%20and%20%20Leak%20Repair

I'll only Post the Important Information which to : FIX YOUR VOLVO for LIFE

so It doesn't Cost You $500.00-$1200 Dollars ! :beer:

 

I'm not sure where aldebaran bought his headliner fabric, but I know that Joann's Fabric carried some headliner fabrics back when I was redoing mine. Hope this helps.

 

This! I'm about to re-do mine (something different this time around) and got the foam backed fabric from Joaan's as well.

 

Yes, I got mine from JoAnne's as well.

 

Up Date Your Photo Links : some of those aren't working .

 

Photo links fixed!

 

The service manual says to remove the windshield first and then take the headliner out from there. Well, I already got it out through the passenger door but had to bend it pretty hard. Car has a crack in the windshield already so I'm taking the glass out and replacing the headliner through there before putting in a new windshield to kill two birds with one stone so to speak. Taking the board to an uphostery shop who will recover it for $90.

 

Is anyone aware of any differences in the S60R's install as compared to this?

I have a SUPER annoying rattle just behind my head that I want to get some foam on or figure out what it is. Will be following this closely.

Thanks for the writeup and sorry for the ancient thread bump .

 

If you get round to it, post some tips. The headliner is pretty much held up by the same anchor points, visor, handles, and overhead console. I got a R that might need this too.