How to Make a Headliner Shell

Headliners are found in cars, trucks, boats, golf carts and other vehicles.

The headliner is the ceiling of a car, truck, boat, golf cart or other vehicle. The headliner comprises a fiberglass shell, which is covered with fabric or vinyl. Some custom vehicles have painted fiberglass headliners that are buffed and painted to match the car's exterior. The headliner tends to deteriorate with time, particularly in older vehicles, as the shell can crack and break. The old headliner will serve as the mold for the new one.

Things You'll Need

• Lint-free rag
• Water
• Duct tape
• Face mask
• Latex gloves
• Fiberglass strips
• Fiberglass resin
• Large bowl
• Small foam paint roller
• Flat-head screwdriver

Instructions

1. Remove the old headliner shell from the vehicle. Slide it out of the plastic headliner clips that extend around the perimeter of the headliner.

2. Wipe down the back side of the headliner shell (the side that contacts the vehicle's roof) to remove dust and debris.

3. Apply duct tape to any cracks or breaks in the original headliner shell.

4. Don a pair of latex gloves and a protective face mask.

5. Pour fiberglass resin into a large bowl.

6. Dip the fiberglass strips into the resin and wipe off the excess. They should be damp with resin but not dripping wet. Apply the strip immediately after saturating it with resin.

7. Apply three to four layers of fiberglass strips. Cover the entire headliner shell (the side that contacts the roof). Each layer's strips should be perpendicular to the strips of the previous layer.

8. Smooth the fiberglass strips and remove bubbles by running a small foam paint roller over the strips.

9. Allow the new headliner shell to dry and harden. The drying time will vary depending on the specific product. The process typically takes between 12 and 24 hours.

10. Separate the old headliner shell from the new fiberglass shell. They typically separate quite easily. If necessary, slide a flat-head screwdriver between the old shell and the new shell to pop them apart.

Tips & Warnings

• In some vehicles, the headliner clips may be covered by the vehicle's plastic panels. They will need to be removed in order to access the headliner clips. The plastic panels typically pop off or they may be fastened with screws.

• Finish the headliner shell by upholstering it. It can also be sanded and painted.

• Purchase fiberglass strips and the resin (sometimes called "fiberglass adhesive") from a local arts and crafts supply store. They're often sold in kits.

• Spray-on fiberglass will also work for this project. You'll require a spray gun and air compressor to power it. The fibers are mixed with the resin in the spray gun jug. You simply spray the fiberglass onto the old shell and smooth it with the small foam paint roller.

• Purchase a new set of headliner clips and keep them on hand. The plastic clips frequently break during the removal and installation process, particularly on older vehicles.