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pbrown
Samba Member
Joined: July 15, 2008
Posts: 443
Location: Seattle, WA
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 Posted: Sun Sep 06, 2015 3:37 pm Post subject: Westy front headliner template |
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I want to build a new headliner for my FrankenWesty and don't have one to compare. I'm wondering if anyone out there happens to have one out of the van and would allow me to trace the shape to make a pattern? I'm in Seattle.
For those that have built their own headliner, what material did you use? I'm thinking about using Baltic Birch in 3mm thickness.
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Patrick Brown
1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF |
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Phishman068
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Joined: February 19, 2007
Posts: 1868
Location: Pittsburgh PA (ish)
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pbrown
Samba Member
Joined: July 15, 2008
Posts: 443
Location: Seattle, WA
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| Posted: Mon Sep 07, 2015 7:20 pm Post subject: |
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I'll up the stakes a bit. I will buy enough material to do two headliners for anyone that may want to take the opportunity to upgrade. One for me and one for the donor of the old headliner.
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Patrick Brown
1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF |
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danfromsyr
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Joined: March 01, 2004
Posts: 15144
Location: Syracuse, NY
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| Posted: Mon Sep 07, 2015 8:33 pm Post subject: |
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we made my brothers from 1/8 masonite
matches his brown interior well
if no one gets you a template lmk in a couple days i could trace one on white poster paper and mail it in a tube for $postage
dan
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pbrown
Samba Member
Joined: July 15, 2008
Posts: 443
Location: Seattle, WA
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| Posted: Mon Sep 07, 2015 9:39 pm Post subject: |
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| danfromsyr wrote: |
if no one gets you a template lmk in a couple days i could trace one on white poster paper and mail it in a tube for $postage
dan |
Thanks Dan.
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Patrick Brown
1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF |
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insyncro
Banned
Joined: March 07, 2002
Posts: 15086
Location: New York
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| Posted: Tue Sep 08, 2015 4:52 am Post subject: |
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| I have a template, but in NY. |
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morymob
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Joined: November 09, 2007
Posts: 4683
Location: east-tn
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| Posted: Tue Sep 08, 2015 5:24 am Post subject: |
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| Problem is how r u gonna get the compound 'cup' shape to make it fit inside of roof? If i ever needed to replace one i would get from an upholstery shop some of earlier ceiling covering, glue it in place. We did the ceiling of my ply voyager, the complete front to back in one piece, replacing orig type, took 4 to hold corners aligned to start, won't be orig but depends on what u want, as usual no warranty offered at this time. |
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insyncro
Banned
Joined: March 07, 2002
Posts: 15086
Location: New York
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| Posted: Tue Sep 08, 2015 6:26 am Post subject: |
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| You have to trace the template in the bent position to get it perfect. |
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Zeitgeist 13
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Joined: March 05, 2009
Posts: 12115
Location: Port Manteau
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| Posted: Tue Sep 08, 2015 9:47 am Post subject: |
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Doesn't it naturally conform to the roof profile with the combination of j-channels on the side and screws front and rear?
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Casey--
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik? |
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insyncro
Banned
Joined: March 07, 2002
Posts: 15086
Location: New York
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| Posted: Tue Sep 08, 2015 10:02 am Post subject: |
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| Zeitgeist 13 wrote: |
| Doesn't it naturally conform to the roof profile with the combination of j-channels on the side and screws front and rear? |
It does, but something tells me from the ones I have here, that it may have been laminated in its shape.
The ones I have look like three layers, similar to luan plywood, but the center lam is run like stringers.
Each was router finished, than the surface layer was glued on.
Each has held its shape much better than bent horizontally laid plys.
I have to check now as I have an 85 and a 91, I will see if they are the same other than finish layer color. |
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Zeitgeist 13
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Joined: March 05, 2009
Posts: 12115
Location: Port Manteau
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| Posted: Tue Sep 08, 2015 10:10 am Post subject: |
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Ah ok, my memory is based upon removing one from my '80 Westfalia
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Casey--
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik? |
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Paulbeard
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Joined: July 10, 2015
Posts: 2604
Location: Seattle
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| Posted: Tue Sep 08, 2015 12:40 pm Post subject: |
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I think by measuring the dimensions, conforming to the contour (think: tailor's/dressmakers tape measure. Or string), you'll get the shape right. You're welcome to look at mine as I am local to you. A flexible material like masonite or 1/8th ply should bend to that curve. I might try poster board or some art board first.
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Currently -> Frida: 87 Tizian Red (mostly) Vanagon GL Westfalia w/ 2.0L ABA conversion
Formerly -> Steward of a 73 Super Beetle (Beater) and 67 Beetle 1300 (Little Max) both names by POs
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pbrown
Samba Member
Joined: July 15, 2008
Posts: 443
Location: Seattle, WA
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| Posted: Sun Apr 02, 2017 8:53 am Post subject: Re: Westy front headliner template |
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I'm getting back on this project. Can someone post a close up photo of exactly where the J-channel is attached on each side? I'm trying to be as precise as possible.
I used a spot weld cutter to remove the old headliner attachment point. I'll smooth this out and paint and then rivet the J-channels in place.
I'll be buying a 3mil sheet of Baltic birth and cutting it to fit. I've seen enough photos online that I think I can pull this off.
I still haven't decided if I want to finish it in the natural wood or cover it with a gray cloth.
I have an extra light assembly that I'll extend over the passenger side.
I'll also be nstalling some sound Dynamat up there while I'm at it.
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Patrick Brown
1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF |
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thunderstick12
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Joined: December 07, 2015
Posts: 7
Location: Washington
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| Posted: Sun Apr 02, 2017 9:20 am Post subject: Re: Westy front headliner template |
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| I'm doing the same thing. My old headliner is in the garage to trace. I just need to get a piece of plywood. I bought some headliner material from Sewfine to put on it. I live In Snoqualmie if you want to come look and trace? Steve |
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davevickery
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Joined: July 16, 2005
Posts: 2887
Location: Fort Collins, CO
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| Posted: Sun Apr 02, 2017 10:48 am Post subject: Re: Westy front headliner template |
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| pbrown wrote: |
I'm getting back on this project. Can someone post a close up photo of exactly where the J-channel is attached on each side? I'm trying to be as precise as possible.
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Here are some pics removing it from a donor 91 Westy
And installed in the syncro
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pomfritz
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Joined: December 18, 2014
Posts: 477
Location: Folsom, CA
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| Posted: Tue May 16, 2017 2:13 pm Post subject: Re: Westy front headliner template |
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Would like to know how these turn out. I am planning on replacing mine soon and was going to trace the old one onto 1/8" ply. Maybe cover it with fabric to match panels, not sure.
Mine has the passenger side cut off so that I could access the area to run new speaker wires. 4/5th's is still attached to the van.
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83.5 233K. GW 2.3, SS exhaust, My German Frau named her Stefi |
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E1
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Joined: January 21, 2013
Posts: 6572
Location: Westfalia, Earth
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| Posted: Tue May 16, 2017 2:24 pm Post subject: Re: Westy front headliner template |
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I'm soon to do all our panels, likely in wood.
Biggest concern is arcing the headliner without splitting it. I know one soaks wood in water for days to make canoes and such, anyone done that for a headliner?
Once the wood is softened, I imagine C-clamping to the original headliner might just be the ticket. I'm buying extra material if it becomes tragic, though...
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‘84 Westy, 2.1L with Digijet, 5.43 R+P, GT Gears
"Adding power makes you faster on the straights.
Subtracting weight makes you faster everywhere."
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plummerdesign
Samba Member
Joined: September 04, 2010
Posts: 540
Location: PNW
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| Posted: Wed May 17, 2017 8:36 pm Post subject: Re: Westy front headliner template |
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Dang.
So right now I have this item out of the bus. Yes indeed the cab headliner panel from the 1983.5 Westfalia under restoration. It is getting a recovering of the Tolex material used throughout the rest of the bus. And it looks SO good.
Making a template from this item is not tough.
Finding a piece of paper that is 54" x 48" is tough. Staples has Natural Kraft Paper 48" w x 200" for $31.00 and it would fold up nice to mail in an envelope. The question is...do I feel like being nice for no reason other than to help my fellow Sambaistas?
Hmmm
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rmcd
Samba Member
Joined: October 29, 2010
Posts: 1349
Location: PNW - its a dry rain.
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| Posted: Wed May 17, 2017 9:13 pm Post subject: Re: Westy front headliner template |
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I have scrap paper that big. I'd be happy to give you a couple chunks to make a template for someone. Oh and I'm in Pdx. PM me if interested.
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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
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pbrown
Samba Member
Joined: July 15, 2008
Posts: 443
Location: Seattle, WA
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| Posted: Sat Jul 28, 2018 8:21 pm Post subject: Re: Westy front headliner template |
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I slowly making progress on the worlds longest headliner project.
I found this photo in the gallery. I'm going to verify some the dimensions but it looks promising.
I've added Dynamat and Dynaliner as shown in the photos below.
I was able to find a sheet of 3mil Baltic birch ply at a specialty shop in Port Townsend WA.
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Patrick Brown
1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF |
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