As far as fiberglass body manufacturing has come in the last 20 years, there remains one area that often leaves owners in a dilemma as to how to proceed. Where steel bodies have all the tack strips and headliner bows integral to the upholstery and headliner, many fiberglass bodies do not. Precisely how to attach the material-covered panels to the body is usually left up to the upholsterer--and is not generally a task the average home-type builder can perform in his garage. This exacting operation requires a good deal of measuring and planning. It also requires practice and experience to complete the task to a competent level.
We recently followed and photo-graphed the talented trimmer Lance Troupe as he installed a headliner in a '36 Ford coupe--and immediately saw the comparison to how a 'glass pickup cab headliner might be created. Starting with the bare shell of the body, Lance created the wood blocks for attaching birch templates, which allow the covered panels to make an interior. With more than a little practice, you might be able to fabricate an interior that may not be quite affordable from a professional trimmer. Here's the first of a two-part story on how the process of creating a custom headliner is accomplished by a professional.
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 The first step in installing...  The first step in installing a headliner in a truck with no provisions for attaching material is to build the header and attach panels... |
 ...Lance started with a rough...  ...Lance started with a rough template and traced the outside contour of the door opening. |
 Once the rough shape was traced...  Once the rough shape was traced out, it could be cut from the rest of the material and further shaped inside. |
 With the template in place,...  With the template in place, Lance trimmed the top parallel with the bottom... |
 ...and trimmed a bit away...  ...and trimmed a bit away from the bottom to clear the windlace. |
 Once the fitment of the template...  Once the fitment of the template is sufficient, it's traced onto a piece of 1/8-inch Baltic Birch and cut out on the band saw. |
 The wood panel was then checked...  The wood panel was then checked for fitment over the door, with the area in the A-pillar and the curvature of the window carefully scrutinized. |
 Notice how the arch in the...  Notice how the arch in the panel follows the door perfectly. This will ensure a tight seal between the headliner, windlace, and door panel. |
 Since the body isn't flat...  Since the body isn't flat behind the panel, wooden blocks need to be affixed to the body so the panel has something to attach to. Again, Lance made a cardboard template and transferred the shape to a piece of wood to be cut to shape on the band saw. |
 Since Lance used fiberglass...  Since Lance used fiberglass resin to attach the wood blocks, the area needed to be clean and free of foreign debris to allow the two surfaces to adhere correctly. |
 A small batch of resin was...  A small batch of resin was made up... |
 ...and the blocks were glued...  ...and the blocks were glued into place. |
 After the blocks were allowed...  After the blocks were allowed ample drying time, they were sanded perfectly flush with the doorjamb so the headliner and door panel meet evenly. |
 The panel was checked once...  The panel was checked once again for fitment--a little trimming was needed in the A-pillar area. |
 A quick hit with the air ...  A quick hit with the air sander... |
 ...and we're back in busi...  ...and we're back in business. |
 Once the fitment of the panel...  Once the fitment of the panel was acceptable... |
 ...it was drilled to accept...  ...it was drilled to accept countersunk screws and attached to the wooden blocks. |
 With the foundation in place,...  With the foundation in place, it was time to attach the tack strip that will ultimately hold the headliner in place. This piece replaces the perforated steel strip that would normally be found in gennie steel bodies. |
 Small staples held the tack...  Small staples held the tack strip in place along its entire length from one end of the panel to the other. |