My D1s have saggy headliners and it is time I stopped putting that job off. Anyone have advice on what material to use and where to buy it? How about adhesive? I thought about reusing the material that is sagging. Is that a good idea? It is a little dirty but I thought perhaps I could put it in our front loader in a laundry bag designed for “fragile” clothing. Worst case scenario is I ruin it washing it and have to buy new anyway.
Also, I do not really want to paint it. I have one that a previous owner painted and it looks like crap.
headliner express used to be the move but they're raised their prices like crazy. you'll need a 64" wide roll, which is extremely hard to find, or you need a 60" roll that can be stretched to fit, which you'll have to ask about.
HIGH TEMP spray adhesive is available in a 16oz. spray can. Can be purchased individually or in a case of 12. This high strength, high heat resistant contact adhesive is ideal for bonding a variety of materials. This includes foam-backed headliners, carpeting, fabrics, jute padding, foam...
glue two cans should do it. spray on the headliner board and the fabric.
Quite by chance I found a place that does headliners not too far away. I’m going stop in and have them give me price. It is one of the few jobs I really don’t want to do myself. I’m going to remove it and bring it to them.Appreciate all the good suggestions. I will post back with what I find out.
Don't fear replacing the headliner. It is pretty easy.
https://www.albrightssupply.com/extr...le-67-orph
Buy the spray on headliner glue at Home depot or something.
- remove the board
- use a cheap bbq grill brush to remove foam backing
- lay out board on flat table
- start in the middle (front to back) and spray glue on both board and material. allow the glue to set for 3-5 min.
- lay the material down and use a balled up rag to press it down. DO NOT use your fingers, they will make depressions that will remain.
- work outwards to the back, then front working 12" at a time.
- leave 1" extra cloth on all sides and fold it over the board and glue it down. Same for sunroof openings. you will need to make relief cuts around corners.
- The concave corners are most difficult. dry fit them first without glue to see how you will need to stretch the material.
Bedsheets…. that actually seems like it could work
I think it’s the Honda crowd that started it. I work with a guy who buys cheap Hondas and flips them. I’m always amazed at how cheap he gets trick shit for his Hondas.
He’s telling me he’s seeing it done. I think it’s going to need to be a light material. A high thread count would be too heavy I think. I’ll find out more.
I know when you look for the stuff they describe it as foam backed headliner material. I’ve been looking into this too cause I’m doing the interior on mine.
While I’ve been looking at what those kids are doing with bead sheets I have a feeling it’s not going to stay up. Headliner material is really light stuff. Pretty sure when it’s hanging down like they all are, the foam backing is still glued up there. I was actually thinking about finding a place that sells the stuff and either go there with a piece of the old one, or send a piece for them to match color on.
The only hard part is scraping off the adhesive from the old fabric, but it's not bad and you have to do that anyway if you replace it with fabric.
Once you remove the old fabric and brush/vacuum off as much of the degraded foam as you can, denatured alcohol does a great job getting rid of the old adhesive residue and leaves a wonderful, pebbled finish. At least it did so on my '99. YMMV. A few days ago someone replied to me on another forum that the headliner on their facelift, '03-'04 had another layer of something that got in the way of them painting a bare fiberglass shell.
I think I remember someone posting up pics of spray on bed liner. You can mix a color into some of those kits of the crap.
I know it’s not headliner related but.. there’s a doctor down in Chicago who built a very nice D90 and mixed the bed liner with the paint he was spraying the truck with for the recessed area around the old style door handles and other places. It’s a pea green truck with a diesel. It’s an Isuzu conversion like they run in the Australian military. Aircraft liquid filled gauges. To this day I think it’s the nicest Defender I’ve ever seen.
Back to headliners.
Bedsheets…. that actually seems like it could work
My D1s have saggy headliners and it is time I stopped putting that job off. Anyone have advice on what material to use and where to buy it? How about adhesive? I thought about reusing the material that is sagging. Is that a good idea? It is a little dirty but I thought perhaps I could put it in our front loader in a laundry bag designed for “fragile” clothing. Worst case scenario is I ruin it washing it and have to buy new anyway.
Also, I do not really want to paint it. I have one that a previous owner painted and it looks like crap.
Hello Terry, thanks for the reply on the Aluminum Radiator. I had my headliner replaced down here in Melbourne, Florida last summer, the shop A & E Auto charged me $500, no cheap, but looks factory and they had to pull work with the rear AC unit in the roof...not fun...it was alot of work, but it turned out..really just OEM, so I am very happy with how it turned out, I also like to wrench on my Land Rover but definitely was not looking forward to the Headliner Job.
I did end up taking it to a local place that was really a hole in the wall type place. I took it out and brought it to them. I haven’t had a chance to reinstall it yet but will report back when I get it back in. They charged me $300. The material looks good but there are some aspects I’m just not sure about yet.
Over the decades, we've learned what makes headliner fabrics perform—and fail—under real-world conditions. Today, we’re diving deep into sagging, repair, and replacement, so you can choose the best materials and methods without the guesswork.
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Drawing on hands-on experience with foam-backed fabrics, vinyl, suede, and more, we’ve developed a clear understanding of each material’s strengths and weaknesses. In this guide, which brings together expert tips and DIY-tested techniques, we’ll walk you through how headliners work, why they fail, and how to fix or replace them to ensure long-lasting, clean results.
What Causes Headliners to Sag?
Sagging headliners are often misunderstood, but the causes are well-known. Here's a breakdown:
- Heat & UV Exposure
Hot interiors soften adhesive bonds. As the foam ages, it oxidizes and the glue fails under heat—making sagging over time nearly inevitable - Foam Backing Degradation
The foam layer becomes brittle or powdery, unable to hold the fabric up, even if the adhesive is still intact - Moisture & Humidity
Leaks or humid interiors can soak into the foam, accelerating rot and causing the headliner to detach - Age and Mechanical Stress
Over time, constant panel flex and surface vibration weaken the foam-glue-fabric bond—especially in older vehicles - Poor Original Installation
Some factory installations lacked sufficient adhesive or prep. That, combined with ageing, makes DIY replacements often necessary
What Is the Longest-Lasting Headliner Material?
Through field-tested usage, these materials have shown superior durability:
- Foam-Backed Tricot Knit (Polyester)
Plush, forgiving, and easy to install—foam-backed polyester often lasts 20+ years with standard care - Carpet-Style Polypropylene
Durable and mold-resistant, this marine-style option resists abrasion and handles contours well—great for longer-lasting results - Vinyl (Foam-Backed or Upholstery-Type)
Water-resistant and UV-tolerant, vinyl suits hot climates or convertibles—though it needs a smooth substrate and trim coverage to hide seams - Suede / Microsuede
Premium look and texture with good durability, but a bit more prone to stains and UV damage—worth it for a luxury interior
Takeaway: Foam-backed polyester is the most resilient and widely used, lasting two decades with proper materials.
How Long Does a Car Headliner Last?
On average:
Material Type
Lifespan Under Normal ConditionsFoam-Backed Polyester
15–25 years
Vinyl (UV-treated)
10–20 years
Suede / Microsuede
8–15 years
Carpet-Style Polypropylene
10–20 years
Quality installation is essential. Even top-tier materials degrade if heat, moisture, or dirt aren’t controlled. Where original foam is failing, even the best fabrics won’t hold. That’s why complete replacement—including foam and adhesive—is often preferred.
What Is the Best Material to Use for a Headliner?
Choose based on your goals:
Want more information on best fabric for headliner? Feel free to contact us.
- Everyday Use → Foam-backed polyester for all-around durability and ease.
- Convertible/Hot Climates → Marine-coated vinyl for moisture and UV resistance.
- Luxury Interiors → Suede or microsuede for upscale texture and feel.
- Utility / Abrasion-Prone Areas → Carpet-style fabrics for rugged interiors.
Other considerations:
- Adhesive Compatibility: Use contact spray adhesive rated for headliners (like 3M’s general trim adhesive) for a strong, even bond
- Foam Type: High-resilience (HR) PU foam lasts longer, up to 20 years, versus cheaper Everlon foam (4–8 years)
- Backing & Breathability: Nonwoven cotton/polyester picks prevent mold but foam is preferred for insulation and structure .
How to Fix a Sagging Headliner in a Car
Temporary Fixes (Quick & Dirty)
- Upholstery Twist Pins
Corkscrew-style pins push the fabric back up—useful for small sag areas - Clear-Topped Push Pins or Staples
Common in forums—cheap and simple, but track visibility and durability . - Spot Spray Adhesive
Good for edge lifts, but won’t fix collapsed foam
These work short-term but don’t address the underlying foam decay.
Full Repair / Replacement
Step-by-Step Process:
- Remove the Headliner Board
Detach trim, lights, visors, and retain the board intact - Strip Old Fabric & Foam
Scrape off deteriorated foam completely to prep a clean surface - Prepare Surface
Clean with isopropyl alcohol; sand lightly if faded or rusted. - Apply New Foam-Backed Fabric
- Use spray adhesive on both board and backside of fabric; let tack before smoothing.
- Use a roller for even contact and to prevent bubbles
Trim & Reassemble
Cut openings as needed, reinstall trim and panels.
- Curing Time
Let adhesive cure per manufacturer instructions—typically 24 hours before reinstalling
How the Headliner Is Fixed in a Car
Mechanics or upholstery shops follow a similar method, but they often:
- Use steam cleaners and specialized tools to gently strip old foam.
- Source OEM-quality foam-backed fabrics matched to vehicle interiors.
- Leave the adhesive to cure in climate-controlled spaces.
- Offer warranties on workmanship—often a better value over long-term DIY concerns.
Professionals also catch structural issues: water leaks, interior rust, or weakened trim—making replacement the more foolproof, long-term solution.
How Much Does It Cost to Do Headliner?
- DIY This Weekend: from $25-30 for headliner material and adhesive
- Professional Replacement: $200–$600 for full redo; high-end or specialty fabrics (suede/vinyl) can push cost to $800–$1,500 depending on vehicle and labor.
- Convertible/Marine Grades: Vinyl or marine fabrics cost more—as materials (~$30–$50/yd), plus skilled labor for seams and finishes.
FAQ
1. What causes headliner to sag?
Extreme heat, failing foam backing, prolonged age, and moisture all compromise adhesives and foam—leading to sagging
2. What is the longest-lasting headliner material?
Foam-backed polyester (tricot) is most durable (20+ years), vinyl for moisture/UV, and carpet or suede for specialized or luxury builds .
3. How long does a car headliner last?
Expect 15–25 years under ideal conditions; vinyl/suede around 10–20 years with proper care.
4. What is the best material to use for a headliner?
Use foam-backed polyester for general use; vinyl for hot/moist climates; suede for interiors; carpet-type for utility spaces.
5. How do you fix a sagging headliner in a car?
Temporary: twist pins or adhesive. Long-term: remove board, strip old foam, apply new foam-backed fabric with proper adhesive, and re-install cleanly.
6. How is the headliner fixed professionally?
Shops use steam, OEM-grade fabrics, controlled environments, and test trim seals to ensure long-lasting results.
7. How much does it cost to do a headliner?
DIY: $30–$80. Professional service: $200–$600 standard, $800–$1,500 for premium fabrics or large vehicles.
Final Tips
- Always strip down to bare board—spot fixes rarely last past summer.
- Choose HR foam-backed fabrics for longevity.
- Use 3M or equivalent headliner adhesives, applied to both surfaces.
- Work in a shaded area on mild days to aid curing.
- Mask edges and holes before reattaching trim for a crisp finish.
Disclaimer
The information provided in this article is for informational and educational purposes only. While we strive to ensure accuracy and provide advice based on years of experience in automotive upholstery, we are not responsible for any damage, injury, or loss resulting from the use or misuse of the information or products mentioned.
Always consult a certified professional before attempting repairs that involve your vehicle's interior components, especially if airbags, electrical systems, or roof-mounted safety devices are involved. Installation steps and product performance may vary depending on vehicle make, model, climate, and condition.
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