Ghia Coupe Headliner - DIY

[Craigbro]

After not finding a lot of information I've attempted to make a DIY headliner for my 64 coupe. I'll provide a short description and a few pictures just in case anyone else may be interested now or in the future.

I started with a 60x40 foam board from the local hobby store. I cut and fitted it a little large to catch the bow spring mounts and provide a natural bow to the top that extend past the lip all around.
Next I used a second foam board and cut it to fit right inside of the lip all around. this board was covered with modern headliner material adhered with 3M-90.
I used the 3M-90 at the edges and secured the headliner to the base board. Note that the headliner board was cut to fit snug so it has the same bow as the first board and top.
I then used carpet binding (Instabind) to provide a trim around the border and also the wrap over the frame between the headliner and rubber seals. I used a coat of contact cement to secure the binding.

A couple of tips:
- I initially used brown paper to get a rough shape and traced it on the foam board and trimmed as needed.
- the foam board can crease easily so work slowly and do not over bend it
- I only applied contact cement to the frame for the binding and let it dry. I tested it on the binding and it leaks through and discolors it.

[kingkarmann]

Thanks for sharing
What did you use for the edging?

[Craigbro]

The edging is the Instabind. Its a binding used on carpets, rugs, etc. Its a non-sew product that I found when researching my next project...DIY carpet

[kingkarmann]

[Tom K.]

I really like your approach here. My '65 currently has an ugly red interior that I plan to replace without emptying the bank. I've listed some questions below.

[Craigbro]

The foam board is 3/16" (got it at Hobby Lobby) - Fyi the outer layers on the board at HL is much better than at office stores. Both boards were the same size.

I did not apply adhesive to the first board. It was wedged in place and the lip holds it in. It was really for a spacer. it is wedged tight to contour to the roof.
I also glued a few pieces in the corners (on top) of the headliner (2nd) board, between the two boards, to get it to fit flusher with the lip of the car.

When I installed the actual headliner board I used contact adhesive around the edges to adhere it to the first board. You could maybe glue the whole board, I was just worried that I might have problems lining it up if it "adhered" too well. Note, the actual headliner board fits inside of the car lip.

I bought bulk headliner material and cut/glued it to the foam board before installing.

Yes, "base board" is the first foam board installed, as a filler board basically.

Hope this helps, let me know if you have any more questions.

[Rome]

Nice work.

[Craigbro]

[Tom K.]

Crystal clear, Craigbro. I'll be doing this. Thanks! I look forward to seeing your carpet ideas.
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'91 Vanagon Westfalia
'70 Beetle Convertible
'71 Super Beetle Semi-Automatic: https://www.thesamba.com/vw/forum/viewtopic.php?t=714131&highlight=
'65 Ghia: https://www.thesamba.com/vw/forum/viewtopic.php?t=762478&highlight=

[John Moxon]

Thanks Craigbro, a very useful option, just added to the "How To" Stickies.
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John.
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My 1958 Shorrock Supercharged Karmann Ghia
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[Tom K.]

[Rome]

[gorbur]

Awesome innovation Craigbro.
I did a similar process on the bug i just finished. I did mine in panels secured with velcro on the leading edge and a thin strip of pvc on the trailing edge (just to retain the alignment of the surfaces). No reason it couldn't be done this way on a Ghia.
The fabric was sourced at a local discount fabric shop. Took a bit of time to find a exterior black with 4 way stretch. 3M #90 sticks it to the close cell 9mm foam. Not evident is a patch of sound deadening material in the centre. Goes a long way to reduce noise.

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73 - Ghia Cabriolet, currently under resto
76 - Type1, 1776, full restomod

[Figment]

wow that looks great.

I used a cheap material when I did my headliner a few years ago. Big mistake, I already want to redo it, and this method makes that prospect far more appealing!
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'71 Ghia coupe

[Craigbro]

[Tom K.]

[gorbur]

In my case it was a bit of both. I used a square foot of Eastwood's equivalent to Dynamat dead centre of the roof (metal vibration). Its crazy how well just a small bit of it works. The 9mm foam / fabric my guess just absorbs any sound bouncing around the cabin.
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73 - Ghia Cabriolet, currently under resto
76 - Type1, 1776, full restomod

[kingkarmann]