[smfdco1]

Today I finished the install of my new headliner. Thanks to the information I found here posted by Vectorit and Zeusflash I decided to go with the FRP available at Lowes. Material cost was just over $115 for three sheets of FRP and some trim strips. Since my original headliner was gone there were no old sections to use as a pattern. The following photos will hopefully give others an idea of what is involved making a headliner.

First item on my list was to find and mark a center line to work from. I started from the rear. Due to the several different curved surfaces I decided to make a pattern for this section out of cardboard. I also cut each piece slightly oversize and trimmed as needed for fit. For cutting I used a set of KETT cutters which is like a nibbler for sheet metal. Worked great, clean cuts and fast. A tip here, find a friend to help you install them as two hands are not enough and four just barely makes it. A heat gun applied to the panel from the back allows you to "pre-form" a bit of the roll to the outer edges. Be careful as the plastic doesn't take much to burn.

The second panel was easier as it is almost a perfect square. Again measure from the center line to the gutter several times and then cut once. It is far easier to trim more off than add it back. At $33.00 a sheet you don't want to make many mistakes. I used the stock "T" channel from Lowes between the first two panels. It fits well and provides a finished edge and forms easily to the curve in the roof line. The front panel was the hardest to fit and I made a template here too. The plastic "T" edge will not work here between the forward edge of the center panel and the small section over the drivers seat. In the last photo below I show the "stock" "T" channel and in the center the one I modified for this joint by trimming off one edge. The original edge fits over the forward edge of the center panel. The "edge" strip (third trim on right) goes to the trailing edge of the forward panel and when in place gives a clean finished edge. I removed the three original metal clips and allowed the headliner to lie flat against the metal roof bows. If measured correctly the seams will line up directly over the roof ribs. A single screw would hold them in place though that was not a problem in my case as I was adding several roof lights for the ambulance use. For $120.00 and three days work I am very pleased with the outcome. Thanks Vectorit and Zeusflash for your write-ups and previous work on your trucks which gave me the courage to tackle this.