sunroof falling to bits

[George Selby]

At 11:37 AM 6/23/04 -0400, you wrote:
>1. The fabric stores sell the headliner with 1/4 inch foam backing. Correct
>me if I'm wrong, but does the Audi use 1/8 inch foam?
>If you use the 1/4 fabric, will you have problems with fit? Especially
>around the sunroof molding,  . . . corners where the healiner meets the
>pillor moldings? Etc? Do you cut away the extra foam at the locations where
>the fabric goes around the edges?
>2. The audi fabric is stretchy, it conforms nicely to the various
>indentations in the headliner. Will store bought headliner conform as
>easily?
>3. Is there a source for the original headliner fabric?
>4. Do you have a procedure for taking out the headliner? Any tricks
>involved? Do the front seats need to come out? etc etc etc


1.  I did the headliner in my Audi 80 last year.  The 1/4 foam worked just 
fine.  VW Jetta was the same way.  When you have the backer board out, you 
will see the material is wrapped around the edges, and then the pillers 
(etc) go ever the new headliner/backer board.  Sunroof is the same way, on 
the Audi the sunroof surround is attached to the car, and when you wrap the 
fabric around  and reinstall the assembly, the surround will cover the 
edges.  The VW used a trim piece that snaps over the headliner and sunroof 
hole, it fit fine even with the extra foam.

2.  The store bought fabric is stretchy.  When you have the backer board 
out and the glue is ready, and the headliner glue is ready, then you place 
the headliner loosely on the backer board.  Start pressing down in the 
center, and work your way out to the edges.  Cut the headliner fabric big 
(like 6" extra all the way around.)  That way you have extra material to 
work with the indentations.

3.  I looked for original material when I did the Audi 80, but couldn't 
find any by searching online.  The color they had (light grey) was good 
enough for me! I used the same color for the Audi and the VW.

4.  Removing the headliner is kinda tricky, but doable.  Even if you tear 
the backer board, when you install the new headliner the glue and headliner 
will hold it in shape once installed.  You have to remove all the items 
around the edge (pillar covers, visors, rear trim around window.)  This is 
probably the hardest part of the job, removing the trim pieces without 
breaking them.  However, if you can remove the sunroof, I have faith in 
you. To get the board out of the car, I either fold the seats as far 
forward or backward as the go (VW seats fold flat.)  Then you spin the 
board 90 degrees and slide it out of the doorway (not the driver's, the 
steering wheel is in the way.)

One last tip, you must remove ALL the old glue/foam mixture from the backer 
board.  A stiff brush helps here.  You will make a big mess doing this, and 
will wind up with a bunch of booger like objects.

Even if there are a few blemishes in the new headliner, it looks so much 
better than a headliner that is sagging that most people will never notice.

I'll be happy to answer any more questions when I return from work (around 
2 am EDT,)  but I've got to go now.

George Selby