Seeing as there is alot of people who need to replace the roof lining from the dreaded falcon roof sag, here is a simple guide to doing it yourself and saving $$$. It takes roughly about 3hrs and it helps to have someone give you a hand.

A few things need to be gathered before attempting this.

- New roof lining material. Roof lining material already has foam attached to back and can be sourced from a good material supplier. If you live in Brissy, you can buy this from a place called SMS (10 Maud Street, Newstead just off of Breakfast Creek Rd). You'll need 1.5m x 2m to do the job and will cost around $45.

- Aquire 2 cans of self adhesive spray. I got mine from Repco for $14.95 each and it worked fine.

- Phillips head screwdriver, cheap crimping tool, stanley knife and some wire brushes.

1. Remove the sun visor and recess clips, passenger roof handles, central interior light and unclip rear passenger lights. Push the central light up through the board so that you can take the board out later.

2. Remove all upper plastic trim panels (most unclip when pulled).

3. Lower front passenger seat back all the way.

4. Remove all black 'Christmas Tree' type clips. This can be done by forcing a flat bladed object under the head, leavering it and then gripping it with plyers and pulling it out. I find it easy to do this with the end of a crimping tool.

5. With all the clips removed, the header board should fall out. Be careful for rotten foam, as it tends to get everywhere and in your eyes. Menouver the board out the back passenger side doorway over the lowered front chair.

6. Strip the old lining off of the header board. You should be able to see alot of the rotten foam still attached to the board. To be able to glue new a liner, this foam needs to be removed. This is best done with a wire brush. Scrape off as much as possible. Also remove the rear light supports. Each support has 4 little clips, just push them in and it comes out. Pay attention to how these supports are positioned and mark them to make sure you put them back in properly.

7. Once the header board is free of old foam, the adhesive spray can be applied. Its best to do this by standing the header board upright so the spray cans dont lose any propellant via application. 1 can of adhesive should do half of the board. Make sure the edges around the light holes and the front dip in the board for the sun visor has plenty of adhesive. A note here, dont spare any glue. Use it all!

8. Place the board on the ground and lay the new roof lining material on top (foam side to glue). Work the lining onto the board going from front to back, making sure the material is properly seated into the front sun visor moulds. Once surface is flat, place some heavy objects onto the board to hold it down while it sets. During this time you can trim any excess material from the sides of the board with a stanley knife. Leave it to dry for about an hour before removing the weights.

9. Turn the board over (on a clean surface as not to get the new lining dirty) and start to cut out all the holes as possible. The 'Christmas tree' clip holes are to small to cut with a stanley knife and can be made with a screwdriver head. Be careful when cutting the holes that you dont push the fabric off the board, this is done by placing 1 hand on one side of the board and using 1 hand to cut from the other side. Watch out for fingers!!! Also place the rear light supports back in. Push the 4 clips through the back plate.

10. By this stage all your holes should be cut, the lining should be firmly in place and you can start to place the board back into the vehicle. This is done basically in reverse sequence to removal. Some tips though, when putting the board in it is probably easier to secure the middle courtesy light first. This will hold the board up so you can secure the sides. Make sure you also put the lighting leads through the holes first.

11. Connect up all the lights, replace all the trim panels, passenger handles and sun visors and there you have a new roof lining.

 

 

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i have some pics with rooflining off and bare if anyone is keen.

Good tutorial mate!

There is a doco on this....

True man, not cuttin yer grass... but this is more than just getting the board out of the car... its also describing how to re-apply new lining to the board once its out!

Fair enough (didnt read ALL of it)...

Maybe combine the two?

Ah good to see that this option is posted as the glueing option is s**t & seeing a person that does uplostering will cost an arm & a leg.