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Originally Posted by Fourt1thirty
Find a good solid headliner card. Unless you car has one this might take some hunting since most headliners have been ripped out already. Some fabric shops stock the proper foam backed headliner material. If you're unsure just purchase it from an upholstry shop. From there go to an upholstry shop and have them glue material to the headliner card, leaving about 4" extra around it. Keep enough scraps around to do all the pillars.
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You can probably save some money by applying the fabric yourself, it's not terribly difficult, all it takes is a couple cans of 3M General Purpose adhesive and some patience.
It's also important to note that the backing board must be clean and free of debris before applying the adhesive and new fabric. Usually, the old fabric falls away from the old backing, leaving the old dried-up foam stuck to the cardboard. I used putty knives to scrape away the excess and a palm sander to smooth everything out.
At an upholstery shop you will pay a little more than at a fabric shop for the material (it's usually around $10 a yard at a chain fabric store vs. $12-15 at an upholstery shop, depending on if they have it in stock), but the real advantage is having more choices. A chain store might stock around 5 popular colors (black, grey, blue, red, tan) but at an upholstery shop there will literally be hundreds of choices, they'll have tons of sample books to look through.
My Rabbit's headliner is the second one I've done, probably the biggest PITA was getting the damn thing in and out of the car because the fabric is tucked under the seals in many places.