Jeep headliner install

When I pulled the old headliner, which was sagging, deteriorating and moldy, I was greeted by lots of light rust. I also pulled the roof rack and installed new gaskets and these excellent roof rack hold-down brackets from Tad @ TTFabworks:

The next step I don't have pics of, but it involved doing my best to scrape all the loose rust and paint off the ceiling and painting it with POR-15 (rust stopper). I wanted to stop the rust and create a good surface to glue the insulation to. So I did all that and painted the crossmembers as well.

I put up the insulation using mainly the crossmembers to support it. The crossmembers created a good clamping power that held up the insulation quite well. It's just too bad I didn't have a long enough piece to go all the way to the front. The front section I had to glue up with 3M stuff for auto trim pieces.

I scored some huge pieces of foam core board from a local salvage store for $5. I used this to recreate the headliner panels. It wasn't too difficult using a sharp Xacto and the old panels as templates. The foam board is perfect for this, very rigid and probably more moisture resistant than cardboard, but it was a little thick.

I bought the material from ebay member "smsheadliners" and got a perfect size to do the whole headliner. I glued it to the foam board using the recommended 3M glue, and it turned out pretty well. I reinstalled with replacement dome lights from newer Wagoneer. For some reason, the panels ended up being a bit short on the sides, so those things that hold the sides don't go over the edges of the panels. I'm working on a solution to this, but it's going to be pretty make-shift.

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