Last few days have been slow progress on this project, something about it got really cold last week so I decided to work on indoor projects...

But this weekend I managed to get started on this again. Getting interior parts cleaned and ready for installation, the biggest headache being the headliner because the front fender and then door have to come off to get it out without damaging it. Decided to re-do the headliner and some of the pillar trim.

Trying to decide if I want to add the base dome lamp to the overhead console headliner - or just leave it alone. Probably just going to leave it alone and put it all back together again. At the moment I'm working out how to replace the failed hook and loop (kinda like velcro but better) pieces with a more positive attachment. Trying to avoid the staples that didn't work on the fiberboard.

_________________
Blow all the things! Wait, I meant boost. Boost!


Runs:
'93 Pontiac Bonneville SSEi - Twincharged, manual, and lots more! Build thread
'97 Chevy Camaro - 3800 supercharged, T5, T-tops
'05 Cadillac STS - V8, AWD, her DD
'92 Olds Trofeo - Fair weather DD
'84 GMC Sierra Classic - Twin turbo 3800
'97 Buick LeSabre - L67 winter DD
'92 Pontiac Bonneville SSE future project

Doesn't run:
'87 Buick LeSabre T-type - future victim
'67 Buick LeSabre - future victim

So after pulling the headliner out of the parts car, I wasn't at all happy with the state of the fiberglass. It was starting to break up around the main attachment holes. The original gray one was about the same. Both were faded really bad, the exposed edges were pinhole melted from heat exposure, the rear sails delaminated and worse off.

I tried to remove the old headliner and foam from the donor without damaging the hard adhesive layer, but that didn't work out. Annoying, but that's how the last few headliners have gone. This time to repair it I tried using epoxy resin. Initial odor is gone in 24 hours, compared to the 4 months of horrible stink I've dealt with using polyester resin (fiberglass resin).


I ended up using a 3" paint roller, wrapped tightly with electrical tape, to spread the resin. By far superior to trying to brush it on. I used the old headliner as a nest for this while it cured overnight. My initial observations are that the epoxy resin, while about 2x's the cost of polyester resin, is far superior. Zero shrink, mild odor during the first 24 hours, and far easier to sand smooth once cured. The headliner on this car measures in at about 5x6 feet in raw material. I'm using a 1/8" polyurethane foam with a polyester scrim backing and 10% spandex faux suede polyester fabric. Details that might prove useful when selecting spray adhesives... Foam side goes down against the headliner backer, 3M and locktite make some good sprays adhesives readily available, but they won't work to glue the fabric to the foam. You need a headliner specific spray for headliners, no matter how light they are. It has a lot to do with the adhesive as well as the spray pattern. You can make 3M 90 or locktite 300 work for the most part, but I've already had a few small failure areas as a result of the spray pattern and material stretch, taking too big a bite in area to wet out at once, etc.


Decided to make the pillars nicer that the Cadillac:


While all this stuff is drying out and curing, etc. I decided to work a bit on some 3D printed parts. First up are the clips for the A-pillar. I broke the first clip figuring out how to take it off - and then every single one after that because they were too brittle...

_________________
Blow all the things! Wait, I meant boost. Boost!


Runs:
'93 Pontiac Bonneville SSEi - Twincharged, manual, and lots more! Build thread
'97 Chevy Camaro - 3800 supercharged, T5, T-tops
'05 Cadillac STS - V8, AWD, her DD
'92 Olds Trofeo - Fair weather DD
'84 GMC Sierra Classic - Twin turbo 3800
'97 Buick LeSabre - L67 winter DD
'92 Pontiac Bonneville SSE future project

Doesn't run:
'87 Buick LeSabre T-type - future victim
'67 Buick LeSabre - future victim

Looks awesome! You're inspiring me to take care of some of the headliner projects I have to tackle, and with more than thumbtacks this time!

I like that you wrapped the pillar covers too, our Cadillac has that pool table felt covering the pillars, if it were a nicer material it would look a lot better. Might have to copycat that myself.

_________________
Will
92 Pontiac Bonneville SSE | L67/4T60E | 77K mi | Med Slate Grey w/ Two-Tone Grey Int. | Low Miles Time Capsule / Storage Occupant
92 Chevy Lumina Z34 | LQ1/4T60E | 177k mi | Torch Red w/Grey Int. | Storage Occupant
03 Buick Park Avenue Ultra | L67/4T65E-HD | 190K | White Diamond Metallic w/Shale & Cashmere Int. | Rust Free Southern Sourced Summer Daily Driver
99 Chevy Tahoe LT | L31/4L65E | 238k mi | Spiral Grey Metallic w/Grey Int. | Daily Winter Rig / Tow Pig and Portable Concert Hall
04 Cadillac Seville SLS | LD8/4T80E | 201k mi | Red Jewel Tintcoat w/Shale & Grey Int. | Nicest Beater Around
09 Chevy Malibu LT | LE5/4T45E | 205K mi | Seafoam w/Blk Int. | Fuel Miser Daily
13 Ford Explorer XLT | 3.5/6F55 | 150k mi | Kodiak Brown w/Blk Int. | Unbreakable, somehow

So I don’t know if I asked this but why not get the headliner material with the foam on it already from the fabric store?

_________________

-Ryan
2004 GTO....LS1, 6MT
96 SSEi...September 2010 COTM........GONE
04 GTP comp G.... December 2015 COTM........GONE
2001 Volkswagen Passat, 1.8T 5MT......winter beater

Because the 90's headliner fabric is just garbage, overpriced, and every fabric store I've been to you have to order it. If I could get the textured fabrics they started using around 2009 I would, but that's not stretchy so it's formed in a press so no real way to wrap it at home. Also this way I can use whatever fabric I like.

Also the underlying design failure, or rather cost cutting measure, of the foam bond to the fabric is not addressed with just buying a new headliner. Doing it this way I'm using a adhesive that's not going to break down the foam over time. So unless I missed a spot the headliner won't sag again.

_________________
Blow all the things! Wait, I meant boost. Boost!


Runs:
'93 Pontiac Bonneville SSEi - Twincharged, manual, and lots more! Build thread
'97 Chevy Camaro - 3800 supercharged, T5, T-tops
'05 Cadillac STS - V8, AWD, her DD
'92 Olds Trofeo - Fair weather DD
'84 GMC Sierra Classic - Twin turbo 3800
'97 Buick LeSabre - L67 winter DD
'92 Pontiac Bonneville SSE future project

Doesn't run:
'87 Buick LeSabre T-type - future victim
'67 Buick LeSabre - future victim

I've been making steady progress, working out details like getting the donor lock cylinders re-keyed, adapting the '98-'99 air bag module to fit the '97 mounts, and going through the interior re-install with a fine tooth comb to do everything possible to make sure there are as few squeaks and rattles as can be. Every loose wire gets taped down, all close fitting parts and joints are getting soft foam pads or felt tape, etc.

Depending on timing constraints, I'm replacing every incandescent bulb in the IP/Dash/interior courtesy lighting with LEDs. I'll be updating the head unit in the Camaro, so taking the one in it now and moving it to the Buick. New speakers to replace the rotting out paper ones, etc.





Working on 3D printing new A-pillar clips! This one is about two versions behind where I ended up.

_________________
Blow all the things! Wait, I meant boost. Boost!


Runs:
'93 Pontiac Bonneville SSEi - Twincharged, manual, and lots more! Build thread
'97 Chevy Camaro - 3800 supercharged, T5, T-tops
'05 Cadillac STS - V8, AWD, her DD
'92 Olds Trofeo - Fair weather DD
'84 GMC Sierra Classic - Twin turbo 3800
'97 Buick LeSabre - L67 winter DD
'92 Pontiac Bonneville SSE future project

Doesn't run:
'87 Buick LeSabre T-type - future victim
'67 Buick LeSabre - future victim

I just broke the two A pillar clips on the 92 SSE today running the mic wire for the new HU up to behind the visor. That one looks much more robust.

_________________
Will
92 Pontiac Bonneville SSE | L67/4T60E | 77K mi | Med Slate Grey w/ Two-Tone Grey Int. | Low Miles Time Capsule / Storage Occupant
92 Chevy Lumina Z34 | LQ1/4T60E | 177k mi | Torch Red w/Grey Int. | Storage Occupant
03 Buick Park Avenue Ultra | L67/4T65E-HD | 190K | White Diamond Metallic w/Shale & Cashmere Int. | Rust Free Southern Sourced Summer Daily Driver
99 Chevy Tahoe LT | L31/4L65E | 238k mi | Spiral Grey Metallic w/Grey Int. | Daily Winter Rig / Tow Pig and Portable Concert Hall
04 Cadillac Seville SLS | LD8/4T80E | 201k mi | Red Jewel Tintcoat w/Shale & Grey Int. | Nicest Beater Around
09 Chevy Malibu LT | LE5/4T45E | 205K mi | Seafoam w/Blk Int. | Fuel Miser Daily
13 Ford Explorer XLT | 3.5/6F55 | 150k mi | Kodiak Brown w/Blk Int. | Unbreakable, somehow