Okay, the headliner install is not done yet, but I think it’s going to turn out fine. So I’m going to post what I did. I like to see a lot of pictures for DIY projects, so hopefully you won’t get sick of this long headliner thread. I’ll reduce the size of the pics to save storage space.
First off, I’ve never done this before on a Sunbeam, but have done a few Mustangs, etc. Secondly, I’m sure if I were to do this again, I’d probably do it different, and better. This is only the way I did it, which was a learning experience. I’m sure the experts would do it a bit different.
Here are the most used tools:
- Rivets and rivet gun.
- 1/8” drill bit to remove rivets. I think I riveted the front cleat 3-4 times before getting it right.
- My wife’s fabric pen that easily wipes off the material, maybe too easy.
- Spring clamps, a bunch. I got these at Harbor Freight, and they really have a lot of pressure. Make sure the clamps are clean so they won’t leave marks on the headliner.
- Poker to locate holes and punch through the vinyl.
- I cut some paint stir sticks ½” x 2” to help hold headliner flat against the flange when gluing.
- Small spring paper clips just to hold while adjusting fit.
- Good glue.
Hardtop will need to have the rear and quarter windows removed, the side furflex pieces, and latches.
I tried to remove the headliner in one piece, just in case I needed to refer to it later. Take plenty of pictures, you can always delete them later. I’m pretty sure this was the original 55+ year old headliner. It was stained a lot, and had a couple tears near the top latch area. Get some thick soft blankets to lay it on.
Who knows how long the new headliner (from SS) has been folded up in the box. So, get it out and let it rest. The wrinkles won’t come out until you start stretching it. I even put it in the dryer on low heat for 5 minutes, not much help. And the weather hasn’t been cooperating enough here to set it out on the sun.
Here it is after drilling the rivets out of the front cleat. It's a good idea to put something like a thin stir stick or metal underneath the rivet as you're drilling it, to keep the drill bit from hitting the body metal as it breaks through the hole. The old jute was in good condition, and still attached pretty good to the top. I did lift it up around the edges mostly to check the top for rust. etc., fortunately looked great. I then used some spray trim adhesive to get the jute stuck back on the metal.
Here is the front cleat, and the bows. I think the correct term for the loop on the headliner is 'listing,' and these are 'listing' rails. Keep them in order, the id paint on mine was very faint. From front to back it should be blue, green, red, then yellow. I marked mine with a permanent marker, which quickly came off after handling. So I center punched dots on the ends of mine. Also clean them with steel wool so they slide easier through the headliner.
I also marked with thin tape where the listing ended on the old headliner. The new headliner comes with the listing longer than the rods, and needs to be trimmed. I cut the front listing at 18" from the headliner centerline, and a little bit longer at the back, 18 3/4". I did make a heavy paper tracing of the bows, just in case anyone may need that in the future.
Next up will be getting that front cleat glued up. As Sean mentioned, you have to get that right or it will look like crap. It took me a few tries to finally get it decent.