Ok, I redid my headliner last night, and it turned out better than I expected.
I was very happy with the final outcome and I figured I would post some info as to make this a little easier for everyone else.
I know there is like 4 other DIY headliner threads, but most of them are only from after the headliner is removed.
I dont have any pictures of me actually removing it, but I'm going to try to sum it all up so that others who try this for the first time have an easier time attempting this.
Also, this is for a 92 Jetta with a sunroof.
Golfs may be slightly different, as I know nothing about the similarities/differences in the Golf headliner.
Screwdrivers (phillips and straight)
Pliers/Channel locks (optional, see below)
Headliner adhesive (9.99 LocTite Headliner Adhesive from AutoZone)
Black plastic clips (1.99 Part#963-055 from AutoZone)
Material of choice (Around 7.00 from WalMart)
Also, I chose to do fleece.
Though it looks good and is durable, its so thick that the actual headliner installation became a hassle.
Use thinner materials.
NOTE: The headliner board is extremely fragile. Be very careful when moving it.
I did all steps myself, but it would be 10x easier with someone helping you.
First off, I removed my sun visors.
Three screws each and then you have to twist the one clip 90 degrees to take it out.
Secondly the rear view mirror.
Twist it left or right, but be careful. It will be tight but it takes a little effort to pop it loose.
After that, take down the sunroof crank.
One phillips screw, and make sure not to lose the washers for it.
After that, remove the light. Push the small tab on the right to pop it out and disconnect the wire.
You can then pull the light/sunroof crank piece loose from the headliner.
It has two clips along the back of it, and two that slide over the headliner in the front.
Pull the back down, then slide it towards the rear of the car.
Be careful with this though, as I broke the clips that snap it in place.
Next, take down your "Oh Sh*t" handles. Each has 4 screws.
Remove the screws in your A and B pillar covers.
A pillar is at the top, B pillar is at the bottom.
Pull the A pillar in towards the dash, its not necessary to completely remove them.
The B pillar though must be removed.
There is a large plastic clip at the top that must come out as well.
Dont lose it because its what snaps the top of the pillar tight.
Pull the C pillars out.
They are only held in by metal clips which can easily be pulled in and out.
Don't take them all the way out either, because let me tell you, they are extremely hard to put back in place.
Remove the trim that surrounds the rear window. It has 6 clips that pop down out from the ceiling. Be careful not to break them.
Ok, now comes the part to be patient with.
I used a flat screwdriver and slowly slid it between the weather strips and the headliner over the doors to pop the headliner board loose from them.
They help hold the entire board in place so its crucial you get them all loose before you take the clips out of the ceiling or there is a good chance you will break the board more.
The only thing holding the board up now is the weather stripping around the sunroof and the 4 large plastic clips in the headliner.
Slowly pull the headliner material from under the sunroof interior trim.
It is glued to the metal under the trim, not to the board.
I used a flat screwdriver to pull down on it in certain places.
Last, take out the 4 large plastic clips.
I had bought the extra clips for the headliner, so I just broke the large flat heads so I could grab them with channel locks and pulled them out.
If you want to save them, then find a gentle way to remove them.
Ok, now to get it out of the car.
I put both seats down flat and lowered the board.
Opened the passengers side rear window (that door doesnt open on my Jetta)
Went to the drivers side rear door and maneuvered the corner out that door.
Move the rear right corner up inside the back window.
Stand the drivers seat up and slide the board down behind the drivers seat.
You will probably have to bend it slightly to get it out.
The front should still be in the front passenger seat mostly.
Slide it across the bottom of the door and out the back drivers door.
Ok, once its inside.
It started out and looked like this.
Peel the old material off.
It comes off very easy.
I broke my board and you can see where.
Its ok, it can be fixed.
You next have to scrub/brush all the old foam off.
I used a coarse grit scouring pad for dishes.
Be very gentle, you barely have to apply pressure.
Also, dont apply pressure to the actual board
I.e. Don't lean on it while you are scrubbing the foam off
Another helpful hint if you are doing this inside is to have a vacuum nearby with a hose to suck the debris up out of the way while you work.
Ok, once all the foam is off, next step is to fix the cracks, tears, etc.
I used aluminum tape. The kind for duct work
Very strong, flexible, and very heavy duty.
Just tape all the breaks back together and all the cracks.
And make sure you get the pieces to fill the whole board in, or make your own.
I used cardboard and improvised where the board broke and I couldnt find the missing pieces.
I also taped the sunroof crank/light area down to make it a smooth, one piece look.
That is optional, though I think it would be harder to do two pieces.
Also, if you do it as one piece, make sure you tape it down so it doesnt move once its on your ceiling and pull free from your fabric.
After I did all of that, mine looked like this...
Now you can lay down your fabric.
Spread it out over the board, making sure its the right direction, long enough, wide enough, etc.
I started at the front of the headliner, and did the right corner, worked to the left.
Spray down about about a 1'x1' area of the board with glue, and apply the material very slowly, pressing and smoothing with your hands.
Make sure there is enough of the material to stick over the edge so you can tuck it onto the back for a clean wrapped look. (about an inch)
Work the whole board like this, always taking your time to get all the wrinkles.
Use your hands to form the creases in the actual board.
After all of that, it should look something like this...
Now is time to flip it over, trim the excess, and glue it to the back.
Once its face down, trim all but an inch from the edges.
Fold that over to the back of the board.
I used All Purpose Cement like that for PVC pipes for this step.
Just swab a bit on, about 6-8 inches at a time, and press the material down.
When you get to corners, cut a notch in it so it will bend correctly and trim away the excess that cant be glued down.
It should look something like this after that step.
Finally, repeat this step to all the holes for your rear view mirror, light, visors, etc.
Also, dont forget the 4 big clip holes too.
I decided not to put the "Oh sh*t" handles back up.
After all the holes are cut out, and the edges glued, it should look something like this...
And you are done finally!
Trust me, when you reach this step, its a good feeling.
Installation is the reverse of taking it out.
Also, I found out the front two holes for the large plastic clips are not the same as the back two.
The front two need a different size clip than the rears that I used.
When I go get new clips, I'll post them in here as well.
As for now though, its fine and dandy in my car.
It has about a 1/2 in. sag right behind my sunroof for the time being, but its not even a slight problem.
Now, after all the work is done, have a drink!
Hell, for reading all of this, have a drink!
I hope this helps someone out, because I know there was more than one step that puzzled me while I was doing this.
It's a bit extensive, but its the complete step by step.
Also, if there is any questions, you can PM me for more details.
Thanks a lot guys!
EDIT: Sunroof panel has been finished for a while, but pictures are just now coming up.
The sunroof panel shows through in the pictures but you cant see it in person.
Also, the fabric on it looks different in the picture, but its the same fabric and looks the same in person.
Around the sunroof panel too, you can see where the red shows because I didnt tuck the fabric up under it like the stock way.
Im planning on taking that trim piece back down and painting that edge black to help it blend in.
Modified by brandonrosensteel at 1:01 AM 4-12-2008