I replaced the headliner in my wife's t-top.
As you can see, the entire liner & backer board was shot.
I used a new backer board from one of our parts cars and reinforced the underside with epoxy resin
I test fit the backer board in place (without the fabric) and then cut out the t-top openings. You will have to cover the entire interior of your car with a tarp for this job, I radiused the edges of the cutout, but had to reinforce the dome light hole with steel straps because there was about 1/4in of actual material left on each side. I bonded the new material with 3-M trim adhesive & then re-installed it. I cut the cloth leaving about 3 inches of extra material around the openings, added more adhesive to the back of the cloth and then wrapped it into the weatherstrip channel. Did I forget to mention that you will have to remove the weatherstripping? I used a sharp chisel to cut through the weatherstrip adhesive. Be very careful not to damage the rubber as it is nearly impossible to find a replacement. You will need help to hold the new headliner in place while you fasten it because the backer board will still be very weak.
The headliner actually looks better than oem because the cloth is padded on the sides where it wraps around. The original method is to install a complete headliner unit and carefully cut through the backing. Then they peel the cut-outs from the headliner cloth which rips most of the foam from it. This project is a pain in the a$$ but you can do it. Good luck!
If I were to do it again, I would cut the openings before I reinforce the board with fiberglass. The oem backer cuts very easily with a kitchen knife or hacksaw blade, but not after it has been fiberglassed.
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[This message has been edited by Gordo (edited 09-13-2003).]
[This message has been edited by Gordo (edited 09-13-2003).]
