Headliner Replacement with Sunroof

[SlowGear]

I don't think anyone has documented their installation of a passenger area headliner in a GW with the "factory" ASC sunroof so I figured there may be some value in doing so.
Mine still had a headliner when I bought it but it was only attached by the C-channel trim at the rim of the sunroof opening, on the sides, dome light and a truckload of stick pins. The cargo area headliner and board were totally missing.


Here is the original faded, drooping headliner.

[SlowGear]

Not much challenge in removing the old headliner given its condition. All the foam backing on the fabric had turned in to a crumbly mess which rained down on me. Some of the foam panels attached to the roof had become semi-detached.

[SlowGear]

Since I really have no idea what I'm doing, I used an old flannel bed sheet for a trial run. I was trying to identify where the material should be glued and just as importantly, where not. Magnets were definitely helpful with this.

[SlowGear]

Spent hours cleaning the foam panels and removing the old, residual glue from all the surfaces and re-attaching the sketchy panels.

I am fortunate that none of the panels are missing and mostly in good condition.

[SOLSAKS]

I have removed then re installed a wagoner headliner without sun roof

yours looks even more challenging

you are doing a good job.

dave in NC

[SlowGear]

Gently bend the side moldings open to clear out the old glue and debris, then remove the side panel to clean it up.





Was able to scrape off the glue and adhesive tape without doing much damage to the panel, then re-installed

[SlowGear]

Using the front molding as a guide, I cut the material to follow the contour of the trim. Then then attached the fabric side of the material with 3-M mounting tape to the back side of the trim molding





Also used mounting tape on the header so the fabric is sandwiched between the header tape and trim tape when the molding is fastened with the nine sheet metal screws.

Now ready to attach the molding/headliner to the header

[SlowGear]

Front molding fully attached to header





Flip side...





Gently pulled the material tight at the center and glued to the sunroof switch bracket. Installed the switch and visor clips.






Rough cut the sunroof opening and added some double-sided carpet tape to hold the material in place prior to making the final opening cut.

[SOLSAKS]

nice !
enjoyed the photos.

dave in NC

[SlowGear]

Glued the forward portion of the sunroof opening



The the rest of the opening



Marked a half inch flap to fold over the rim



Glued the flap to the upper rim of the opening



Reinstalled the c-channel trim on the opening

[SOLSAKS]

oh yeah.

dave in NC

[SlowGear]

Working toward the back beginning with the dome light






Rinse and repeat





Fumes are getting pretty intense by now




Home stretch

[SOLSAKS]

beautiful job mike,......congrats !

dave in NC

[SlowGear]

beautiful job mike,......congrats !

Thanks! It's getting close.


Tucking in the outside edge material to the side trim









Reinstall the front corner trim and it's just about done







Sun visors re-covered and ready to install

[bluehwy]

Where did you get your material? I'm looking at BJ's and Team Grand Wagoneer. BJ's description says theirs isn't for sunroof but can be modified to work. Nervous to pull the trigger without any more input than that.


Can you show more pictures on how you did the visors?


Thanks!!!