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duh57 01-20-2013 11:21 AM

My project is a 57 chevy sedan delivery {my Hotrod}. I have spent years working on other customers projects and finally now my own. The frame ,running gear,motor, exhaust are complete. The body is on my rotisserie for complete restomod but i am contemplating the interior and thinking about making a one piece headliner, could someone help on how to make the headliner foundation? I guess im to oldschool for the large high tech headliner :rolleyes: I am new here, will post pictures later. I think now is the time to do it , because i can work on it with it upside down.

DanTwoLakes 01-21-2013 07:21 AM

The base is made from 1/4" luan plywood. You just need to have something solid to attach it to. If there are metal roof braces to screw it to, you are good to go. If not, you need to fabricate braces that run from side to side. The braces are made from 3/4" hardwood plywood, should have a slight curve to them to match the roof line, and do not touch the metal of the roof. You can attach the braces at the ends with some of the new epoxies, or I have used metal "T" straps with the "T" part screwed to the areas above the doors. I then make a grid by running more braces front to back. If you do this right, you can hang from the grid. You use hardwood plywood to prevent warping. I then use 1/8" PVC foamboard to glue whatever fabric, padding, and design that is needed.

duh57 01-21-2013 01:12 PM

Dan thank you for your reply. I have metal braces to attach to,the thing i cant figure out is how to make the compound curves in all 4 corners down to where the fabric or learher attaches ? maybe fiberglass or hard foam board ? Both sides and front and rear should have a smooth curve down to winshield and top of doors. I have a large sheet of 1/8 " ABS I might try to form it in, what do you think ?

DanTwoLakes 01-21-2013 01:46 PM

ABS is really heavy and hard to work with compared to PVC foamboard. Once you get the 1/4" luan plywood installed, you make the PVC foamboard 5 or 6" less all the way around the perimeter. Stitch around the perimeter of the PVC, glue the whole assembly to the plywood, and then you can finish the edges off just like a regular headliner. If you need to make some panels for the sail area, so be it. Look at this thread, you may get some ideas:

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