an inexpensive way to put in a headliner if you just want something
to cover the bare metal roof:
Get a 4X8 piece
of thin plywood paneling (should be plywood, the particle board
or masonite stuff will sag eventually).
Line up the
paneling in the center of the roof and trim the front and rear edges
to fit. The front will need the most trimming. It will fit the flattest
part of the roof, but won't be wide enought to fold down to the
inside "gutter". Don't worry about this yet.
Find a lightweight
indoor/outdoor carpeting that you like. I used a dark brown ribbed
carpet, figured the ribs would help absorb a little noise. I don't
think the foam-backed stuff is light enough.
Glue the carpet
to the paneling using liquid nails, leaving about 6 inches of overhang
along the edges. Mine took about a quart of glue.
When the glue
dries, attach the paneling to the roof ribs with screws and trim
washers starting in the center. I marked the rib locations along
each side and used a string to keep the screws centered on the ribs.
Don't forget to cut a hole for the interior light wires and pull
them through. When all the rib screws are in, trim the overlapping
carpet with a razor or exacto knife so it just tucks up behind the
inside "gutter" trim. It's stiff enough to hold itself in place,
won't need any glue here. You'll get the idea as you go along. Cut
holes in the front for the visors and their trim pieces.
I had with mine was cutting the carpet too close along one edge
so it doesn't quite stay tucked behind the trim.
You may also
want to slide a piece of 3/4 inch foam insulation in between the
ribs and the roof. MIne already had one put in by the former owner.
looks better than I thought it would, most of the time the headliner
is not noticed unless it is falling down on your head.
I think this
is the cheapest way to go and only takes an afternoon or so.