Here's a few shots of the headliner process, to show some of the steps. My headliner panel is a contoured piece that follows the shape of the top, front valance and has a lip at the back to join a wrap panel from door to door. I needed 1/4" foam on the sides, back and front to help fill gaps between panels, but I did not want to give up any headroom so I finally settled on a simple shaped insert that would have no foam above the seats. The center is tapered a bit from the radio console, getting a bit wider in back, and leaves about 4" at he back and sides for the foam. This meant that I was going to have to cut the foam in a rectangular shape, but also that it had to be aligned for symetry both side to side and front to back. I struggled with this for a bit, and finally cut a pattern from luan plywood of that shaped insert. After sanding the headliner to give it some tooth for glue and using my paper pattern I taped off the inserts to keep them free of glue, so that the foam would not stick in that area. Then using the luan pattern I aligned it on one side and drilled three 3/32" holes in a line, so that three common nails could be used for pattern alignment after the foam was in place. I inverted the pattern for the other side, aligned it carefully and used the holes already drilled to drill the headliner panel. Finally time for glue, sand the foam gently, spray both and let them dry thoroughly, and place the foam, smoothing from the center out. Here's a few shots:
Glue on, masking removed, ready for foam:Headliner & Panels 001.jpg
Foam on, nails in place from the bottom:Headliner & Panels 004.jpg
Luan Pattern in place, ready to cut:Headliner & Panels 005.jpg
Finished Headliner Panel, vinyl on, dome light in place:Headliner & Panels 006.jpg
Test Fit with Radio:Headliner & Panels 008.jpg