Why do aftermarket headliners suck so much? Options

[CrashTestDummy]

We're updating some bits in our 92 B4C 1LE Camaro RS ex-Tx DPS car, like headliner and carpet, to start. Both have enjoyed decades of police use and life as a race car. The headliner fell years ago, but since I wasn't DDing it anymore, I didn't worry much, but quietly gathered parts while I was working and tucked them away in our shop. We are finally mostly-done with the restomod of the SVO, so I figured that it was a good time to start on the Camaro. I'm STILL gathering parts, as things have broken and been discovered missing while disassembly progressed.

Since I'm waiting on parts, I figured I'd get the headliner down and unpacked so I can figure out what I need to do for the install. It's one of those ABS things that everyone complains about. When I was buying, the reviews seemed to be all 1's or 5's, and not having much choice, bought one. I think I got it from Hawks, but am unsure. I know they just resell one of the couple that are on the market, so kwality issues really aren't on them.

When I pulled the thing from the bag, I discovered that parts of the material are ALREADY sagging, and it seems the foam between the backing board and material has deteriorated. When you touch the material, it leaves an indentation in the fabric. (IMG:style_emoticons/default/banghead.gif) I'm kind of pi$$ed at this, but also kind of relieved we didn't install this thing only to have it fall while in the car in little time.

I'm not sure what to do at this point. The old headliner board is broken in several places, in spite of trying to go easy with the removal. It was a cheap POS, too, so I'm not sure it can be reused. I'm half-tempted to pull the material off the 'new' ABS board, cleaning it, and then getting and installing some new material, but my last experience with that job years ago was a total failure (headliner on a '83 Impala).

Does anyone know of a good manufacturer to order from? This crap sux!!

(IMG:https://media.fotki.com/2v2ZKPNT8xJDYiP.jpg)
Entire new headliner after pulling out of the packaging.

(IMG:https://media.fotki.com/2v2ZKPrUrxJDYiP.jpg)
Edge by B-pillar showing sagging material.

(IMG:https://media.fotki.com/2v2ZKPrt8xJDYiP.jpg)
Edge of headliner showing depression where it was handled.... a couple of years ago!

This post has been edited by CrashTestDummy: Apr 15 2025, 09:09 PM

[Rentedmule]

That sucks! I don't have any input, but my car needs a headliner too, so I'm here for information.

I was planning to bring my car to a local upholstery shop to get their opinion. I was hoping they could just repair what I had rather than gamble with aftermarket stuff.

[CrashTestDummy]

If they're experienced with that sort of thing, possibly. The headliner panel, at least on the 3rd Gen cars, are a really flimsy fiberboard-like material. Not the old-style cardboard you're used to seeing in earlier vehicles. Ours seemed to be trying to fold up under the weight of the headliner material when trying to remove it. I was trying to be extra careful, too, in case the need arose to reuse it. Not sure that's possible now. I am going out today to have a closer look at it, to weigh my options, if I have any......

The old headliner, at least on the 3rd Gen, also has clips that clip into the roof panel up at the windshield that none of the AM panels have.

[CrashTestDummy]

I think a semi-popular R&R method is to coat the old board in either fiberglass resin, or polyurethane. One guy on the Third Gen list showed a picture of what he did with his T-top panel, and it looked coated by something. I'm hoping he comes back with an answer, or I may step out on my own on this. I've ordered roll headliner fabric from OC Carpets, so I can make a definitive decision when that arrives. If I can repair the old board, I'd prefer to use it, since the AM ABS piece is a bit shorter, and doesn't have the. front clips.

This is about the third 'compromise' I've come across updating this thing. Parts for our SVO were rarely this bad. I commented to my wife that it seems like the vendors are catering to a different class of people providing parts for the GM crowd vs. the Mustang crowd. Maybe with the cars getting to be worth more, and more 'pro' shops doing restorations on them, the market will improve?

While waiting for parts, we set to work on fitting the carpet. After about 3 hours, we're both done, so we let the carpet 'relax' in the car overnight so we could rest up. It's been through 3 iterations of pulling and cutting and reinstalling, and still needs work. I'm trying to sneak up on a good fit instead of 'I cut it off again and it's still too short'.....

The carpet is about 6" too big in each direction, even when laid over the trans hump.

This post has been edited by CrashTestDummy: Apr 16 2025, 09:33 PM

[Rentedmule]

Aftermarket parts availability seems to be improving for 4th gen cars, although I don't know about quality. I'm hoping you're correct and their increasing value encourages more vendors to produce quality stuff. My car has more than doubled in value since I bought it - it's still not worth much, but I like the trajectory!

I was going to mention reinforcing the panel with fiberglass. It seems like that could work.

[CrashTestDummy]

I'm thinking so, too. Since it seems I'll have to roll my own, might as well do it using a backer board that actually fits, and has the proper clips, although I do have to reattach one. That'll also be easy with the fiberglass.

The replies on the third gen list have been 'it's been done by several', but I'm not finding any posts outlining the process used. Maybe it's just that stupid-simple, but inquiring minds want to know, and all. Waiting for a couple of responses, but may start testing with the little bit of fiberglass repair kit I have here now to see.

[CrashTestDummy]

Parts are on. order to use the original backer board. The front retainer clips are still apparently in the GM catalogs, and I've ordered a set from Jeg's, but they have yet to let me know if they've shipped. Same with the fabric and replacement sail panels. Ordered from OC Carpet, but no shipping notification.

While I WOP, I've started coating the backer board with fiberglass resin, reinforcing broken/cracked areas with fiberglass fabric. Here's where I reinforced the area around the dome light hole. This is the side closest to the metal roof panel:

(IMG:https://media.fotki.com/2v2ZK8qcNxJDYiP.jpg)

Flipping the panel over, I've started coating the fiber with resin. The area of the panel below that looks like blood was spilled on it is the reinforced area. This stuff SOAKS up the resin!! I've almost completely gone through an entire 28 oz. can of resin and barely have just the edges covered. Also, since it's fresher than the stuff I started with, it sets very quickly!! My co-driver is going to pick a couple more resin kits up on the way home from work. When we have time in the shop again, I think both of us will be out there, one mixing and pouring, and the other madly brushing the stuff out before it disappears in the fiber of the. board. Here's the other side of the board leading edge. The little squares are the back side of the anchors for the retaining clips. The anchors are basically big staples. I contemplated removing them and installing them in the AM ABS board, but since it's not even dimensionally correct, will stick with the OEM board:

(IMG:https://media.fotki.com/2v2ZK8qwrxJDYiP.jpg)

[CrashTestDummy]

We finally got the old headliner board coated in resin and fiberglass fabric. Tried doing it in two big sheets, but it really wouldn't lay down and kept pulling up as we brushed resin on it. So we ended up doing it in random strips. It's all covered now. Just waiting for the fabric to arrive. (IMG:style_emoticons/default/dry.gif)

We coated the side the fabric will adhere to. I've seen both sides done, usually only one side when done, but there seems to be no reason to do one over the other. I figured the 'glass and resin would provide a nice smooth surface to glue the fabric to, so went with that.

(IMG:https://media.fotki.com/2v2Z1Q8M3xJDYiP.jpg)

It looks much better in person, but really doesn't matter since it'll be covered with fabric.

Now, on to the carpet, which fits about as well as the aftermarket headliner. After days of letting bricks set on it, it's still kind of wrinkly, so have ordered a steamer so maybe we can get some heat and steam on it to help it lay down more/better. I watched a yuutoobs video of a guy installing some, and his opinion after the install was that it fit 'okayish'. NOT very confidence-inspiring with the product.

This post has been edited by CrashTestDummy: Apr 28 2025, 02:06 PM