Originally Posted by hotmomma52204
I recently joined on here seeing some good advice on diamond tufting for seats. Here is my delimma. I have a customer that wants this done on the headliner of his 2008 dodge quad cab pickup. . . in Naugahyde. However, I can't find any foam that would be thick enough to really pull this off that comes more than 24" wide. I haven't removed the old headliner thinking that maybe I could leave it and add another layer of foam over it then the naugahyde. My fear is this would be to heavy and would fall plus the foam still wouldn't be thick enough to look like more than a piece of material with a bunch of buttons on it. The thickest foam I have found that would be wide enough and long enough is only a 1/4". Help?
Then you don't have very good sources available to you for foam. I can get any thickness, any quality, any density, any width, any length from my supplier the next day. To pull this off, and make it look right, you need at least 1" foam in a higher density. 1 1/2" in a slightly softer density would be better. You only need a piece maybe 60" by 72". Tell me what you need in a PM, and I'll have it shipped directly to you. If you have access to 1" or 1 1/2" foam, you could edge-glue it together to make the size you need. Use# 22 buttons (about 1/2" in diameter). Threaded nails or prong buttons would be best. If you can't make these yourself, I can make them for you.
Use the original headliner, mark off the tufting pattern on that, drill 1/8" holes through the headliner, duplicate the pattern on the foam, cut 3/4" to 1" holes through the foam for each hole and tuft. It will never sag or come down, although you may need some extra attaching points for an overhead application. You won't need lag bolts or anything that heavy, the tufting will only add about 5 pounds to the headliner.
Apparently you never lived through the "Custom Van" craze. I did a van that was diamond tufted from one end to the other from halfway up the walls and all across the ceiling. About 500 buttons in a 5" by 7" pattern. My hands still hurt from that one!