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I found that none of the headliners had the correct pattern, texture or weight; they were all wrong in some way.
I found that world upholstery was the only source for the correct material…. I don’t know if they make headliners or just have/sell the vinyl… https://worlduph.com |
what a shame!'
Thanks @showdown - ill take a peep at their stuff |
ordered a sample from world upholstery - thank sagain for the tip
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I got my samples in today from World Upholstery - it looks like the thickness is correct but spacing is the same as the GAHH and texture similiar-ish
http://forums.pelicanparts.com/uploa...1651878932.jpg OG on top with the measurements sniffin around, it looks like Dansk might be close? thickness seems thinner but who knows http://forums.pelicanparts.com/uploa...1651878932.jpg This is apparently a dansk headliner, looks like the zip might be silver tho - anyone here have experience with it? or is it possible my headliner is different than most? |
Odd, on my 77 the world upholstery sample 5005 was spot on.
Now if you really really want perfect I found a perforation company that will perforate anything you send them and make a custom die with whatever pattern you want- no doubt it’s not really plausible for one headliner but if there was enough interest and the costs could be brought down… |
its all good! im sure they change their suppliers often; what you're suggesting tho is a good idea - im sure with enough interest here on the forum it could get done. Im sure there is a lot of folks who want the most accurate as possible
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Foam Setup
For my future carpet - I wanted to pay close attention to the rear section, since its a focal point when people scope out your interior or get in the car for that matter - getting the rear seats lookin smooth and solid was a high priority! This took a few weeks off and on with work stuff i have had the past month - so not as fast as I was hoping but got it done with the time I had. I really liked the quality of the replacement seat pan - and it fit great! I just realized however with doing the foam how DIFFERENT this side is vs the old... but I was finding that nothing is truely symmetrical in this car - everything is slightly different and looks like it was all eyeballed to some degree I used a few thicknesses of closed cell foam since my insulation was already 5-6mm The main idea was just to get the foam to reach above the extrusions in the rear - so it appeared smooth with no hinges etc exposed After I felt comfortable with the hinge area I wanted to shield it with a piece of foam to clean it up and sand it down. Both sides needed to be worked heavily - and I still need to adjust the right side here to be a bit more rounded to match the left side. Easier to add material here than trying to get it to be a sharper radius on the left. 2x rolls of Siless 314mil - 8mm 1x roll of Siless 157mil - 4mm 2x rolls of Dynaliner - 1/4" (6ish-mm) gonna prob need more of this since they dont give you much I wanted to use the tougher foam (siless) in the rear to sculpt and sand the seats a bit, since there were lots of wobbles and bolts etc to cover up. This was also helpful filling up voids as well with foam. Layering and slicing away at it with a long saw blade was great - the long blade was bendable to work with the shape of the seats but also providing enough length/real estate to guide your hand in the correct ways. If i had to do this again: -I would for sure tack more of the foil again more frequently with tape and in more spots. Just like doing the insulation templates, I was finding the foil was moving slightly despite being tacked down - thus resulting in templates that were a little off. -Have plenty of razor/exactos on hand, they got dull quick and my edges lost their clean shape -Same as the past note, having more saw blades would be helpful - the blade I was using was getting a little dull/clogged up with foam adhesive. -When making templates, and cutting them out: your braing really wants to correct wobbly lines with your cutting etc, but you really gotta fight that perfectionism - its wobbly for a reason... hahaha nothing was symmetrical exactly in the car so far - everything is slightly off here and there. I had to do a few templates over a couple times since I tried to make lines much smoother -Buy HEAVY DUTY foil I started with some thick foam on the base of the seats knowing I'd sand it flat eliminating any ridges in the seat pans (i filled the gaps the best I could with the thinner foam) http://forums.pelicanparts.com/uploa...1653263601.jpg http://forums.pelicanparts.com/uploa...1653263601.jpg I spent an unimaginable amount of time filling the void around the hinge for the rear seat backs. I did this a few times trying to figure out the best method. In the end keeping it simple was best. I filled it in layers like a cake starting from the bottom - just building the foam up high like a skyscraper - and then shaving the excess material to the shape of the hump with the saw blade. Since the hinge wasnt really centered exactly and a little wobbly in this area - i took advantage of that dense foam and sculpted/filled/sanded the areas a bit to really make it feel clean. http://forums.pelicanparts.com/uploa...1653263601.jpg early stage http://forums.pelicanparts.com/uploa...1653263601.jpg The left side had a bit of a wobble happening where the seatbelt is anchored, so I filled this in and shaved it smooth the best I could to match the opposite side. I would lay a towel over the top of the hump here and there checking the lines and feel it with my hand to see what needed to be shaved/sanded Once I felt comfortable with the layering and build up - i layed down a cover for everything to simplify and possibly protect the layers. This really cleaned it up and allowed me to sand some high spots. http://forums.pelicanparts.com/uploa...1653263601.jpg The right side in the end still needs some more foam, to round out its radius near the hinge area - much easier to just add foam here than make the left side much more of a sharper radius. Ill do this as we get closer to installing the carpet for time sake, ill keep this mainly about the hump - since that was ALL the work - everything else was just a matter of measuring/making templates and laying/feathering foam with the sawblade. http://forums.pelicanparts.com/uploa...1653263601.jpg The finished result - I will more than likely go back and fill lil gaps and probably tape the seams to clean it up further. http://forums.pelicanparts.com/uploa...1653263601.jpg http://forums.pelicanparts.com/uploa...1653263601.jpg the siless has a strange sheen/texture and looks a bit weird in photos. I couldnt help but lay down the carpet just to pretend - I think it looks pretty good - very happy with what MIGHT be if i can pull it off. Despite the carpet just "floatin" im excited http://forums.pelicanparts.com/uploa...1653263601.jpg |
Short out of context post today
finally got out the crazy viper car alarm - this thing was wild. http://forums.pelicanparts.com/uploa...1653784961.jpg big wild solders, but i suppose it could be worse I didnt plan on getting a new harness made but I def wanna get it sorted now! http://forums.pelicanparts.com/uploa...1653784961.jpg hoping nothing was lost on my end to shoot this over to @timmy2 I mainly wanted to show how filled up my smugglers box was - pretty fun! Went to check it out since I am getting ready for the AC install soon http://forums.pelicanparts.com/uploa...1653784961.jpg http://forums.pelicanparts.com/uploa...1653784961.jpg http://forums.pelicanparts.com/uploa...1653784961.jpg http://forums.pelicanparts.com/uploa...1653784961.jpg was pretty packed in, and i found a few wires that some mice must have taken at some point, bit of a bummer but thankfully ill be getting the wiring sorted soon - to me at a quick glance, this looks like possibly gauge lighting wiring and some other gauge stuff maybe? Anyone have thoughts? |
FWIW, I found some VW Beetle headliner material at an auto upholstery shop many years ago. Looked like the original Porsche stuff to me.
If I had it to do over again I would have used a similar material without the holes. I did this in my '67 Beetle and really like it. I guess if you want originality, that won't do. My Porsche http://forums.pelicanparts.com/uploa...1653850725.jpg http://forums.pelicanparts.com/uploa...1653850743.jpg My Bug. http://forums.pelicanparts.com/uploa...1653850774.jpg BTW, I sewed my own. Of course, I have no sunroof, which made it easy to do. |
is it just easier to not worry about stretching the holes out during installation? (the reason for avoiding the holes)
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Quote:
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I knew I would get deeper into this stuff
I figured, I am never gonna wanna take this dash out again for a bit - so I asked timmy2 to put together a harness for me, but in order to do that; I gotta remove the old one. Happy to see there wasnt TOO much rust, and it was manageable! Tomorrow I will actually get to yankin' wires (hopefully) http://forums.pelicanparts.com/uploa...1654393353.jpg http://forums.pelicanparts.com/uploa...1654393353.jpg that smile is all gums! http://forums.pelicanparts.com/uploa...1654393353.jpg Anyone recognize this oil cooler? |
Fun thread to read and now follow.
Keep up the great work. |
“Fun” part will be separating the dash harness wiring from the through body harness wiring at the gauges. Good to see lots of labels and I’m sure a ton of photos.
Makes installing the replacement easier. |
Thanks Skinnerd
Quote:
http://forums.pelicanparts.com/uploa...1654474965.jpg |
You’ve been busy since we talked.
Keep on keepin on…. |
following
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After futzing with the wires, I would like to just grab new contact switches for the doors/hood/glovebox etc
https://cdn4.pelicanparts.com/catalo...60100-M100.jpg door switch 964-613-601-00-OEM is there any issue with not going with this product number, and perhaps going with URO over genuine in this case? |
The label maker has made this much more tangible than I originally thought - I probably wouldnt want to do this without one period.
I would rather opt for the heatshrink labels tho, these arent as sticky as one would hope. Everything almost out... but trying to muster the courage for the through harness I was pretty surprised at the state of the wiring, it was in better shape than i expected in some parts (in no means is it like a A or B rating) , but also incredibly tangled as well for no real reason. http://forums.pelicanparts.com/uploa...1654820135.jpg |
Wiring Harnesses
its been mentioned a few times in the thread already, but I was pretty concerned at the quality of the wiring in the front of my car. The gauges were pretty mangled, and i am surprised they were working. For peace of mind I am yankin em' since when else would i be able to do this peacefully? http://forums.pelicanparts.com/uploa...1656285730.jpg For the through body harness, it was trickier than what I expected: the wiring harness is slightly twisted around the torsion bar on the psgr side and the transmission mount needed to be removed in order to pull it out cleanly. In my case due to where I live, a lot of the work needs to take place outside - so the transmission slid slightly while jacking it due to a uneven surface no doubt - and the engine/trans wasnt straight and ended up pinching the harness a bit behind the engine... so that plus the heat resulted in a much longer experience removing this harness. http://forums.pelicanparts.com/uploa...1656285730.jpg I wrapped the labeled wires in cellophane and tape to keep the labels from popping off and help it slide thru the body with ease. I tied some twine to the harness so i could easily fish the wires back through, however mine snapped - but i did manage to get a wire puller so this should make installation much easier. soapy water (dawn+water in a spray bottle) was the real hero in getting this removed it really did slip out with ease after doing this. Super happy to have this done with as the wiring harness in the rear is lookin real ratty - going to get the engine harness done when I go EFI in the future and know more about what kind of system i get. http://forums.pelicanparts.com/uploa...1656285730.jpg The connection to the engine harness was really brittle - i unhooked it, and it fell apart in my hand. http://forums.pelicanparts.com/uploa...1656286699.jpg This took a few weeks to accomplish due to my time,bugs, and the socal heat would probably only take a few days if in a garage with some fans and ample time These are now off to timmy2 once i can get a big enough box! Things that would have made this easier:
http://forums.pelicanparts.com/uploa...1656285730.jpg |
Its been a bit! there has been a lot of work i have been doing on the car off and on;
just around the time i removed the wires all out my dad got pretty sick and was hospitalized. So the progress definitely slowed down a bit, but I am getting things done here and there where and when I can! I wanted to show here some of the wiring that Dennis returned to me as it came out beaut! http://forums.pelicanparts.com/uploa...1683916383.jpg http://forums.pelicanparts.com/uploa...1683916383.jpg my ignition far right was pretty burnt, cut up, and on its last leg - Dennis did a real clean job whippin up a new one center, along with the lighting on the far left http://forums.pelicanparts.com/uploa...1683916383.jpg Classic Retrofit Fuses all wired up http://forums.pelicanparts.com/uploa...1683916383.jpg http://forums.pelicanparts.com/uploa...1683916383.jpg Cleaned up my oil fan wiring to feel more oem as well! http://forums.pelicanparts.com/uploa...1683916383.jpg New Engine Harness since I am going EFI/ITB http://forums.pelicanparts.com/uploa...1683916383.jpg New Harness for Link ECU/COP setup http://forums.pelicanparts.com/uploa...1683916383.jpg a big reason for going efi was to A. eliminate the CIS B. Start fresh on wiring since there was a LOT going on in this rear corner of the car along with all the CIS I also have a big problem with not going overboard with this **** http://forums.pelicanparts.com/uploa...1683916383.jpg Next up, my piece I worked on is a rather thorough restoration of my tail lights - which will get its own post |
Tail Lights PT 1
http://forums.pelicanparts.com/uploa...1684002755.PNG (the contrast/black mismatch on the border of the tail lights were driving me crazy along with the bubble'ish look where the paint was just missing) I wanted to refresh my tail lights - since I was redoing a lot of the wiring, but also needed access to a few things here and there. I think I went above and beyond a bit on what was really needed for the tail lights here imo - I think the exercise was to
If you're doing this yourself, id imagine just painting them is more than enough. Like most of our older cars - the tail lights seen a lot of kickback from road debris as well as just aging in general. The p.o looks to have setup some tow light wiring and in part cut the wires up a little bit and the harness was just loosey goosey in the hole where the wires come through to the engine bay on the driver side. http://forums.pelicanparts.com/uploa...1684003148.jpg http://forums.pelicanparts.com/uploa...1684003148.jpg the caps were pretty beat from all the chips with a lil rust here and there - simple de-greaser cleaning to get an overall gauge on how they're holding up http://forums.pelicanparts.com/uploa...1684003148.jpg the tops were pretty bad on both sides (not horrible) but pretty bad http://forums.pelicanparts.com/uploa...1684003148.jpg the inside of the door and tail light housings were pretty good - suprising it was pretty much rust free - just had some nasty caulking or something here that plucked right off no problem. http://forums.pelicanparts.com/uploa...1684003148.jpg after cleaning and hitting it with a brillo a hole broke through real easily - just as if it was a cracker - i tried to poke out any of the delicate metal that was donezo http://forums.pelicanparts.com/uploa...1684003148.jpg did my best to use some rust stoppers and such and clean this the best i could At this point I was figuring I would grab some new tail lights just to go easy on myself, and then I saw the price tag.... (I was also contemplating the lightweight housings on ebay that a user here from the forum makes but they'd need different wiring harness etc - however they do sit flush after the lenses on which is rather desirable imo so i think at some point i will swap) so off to the next step http://forums.pelicanparts.com/uploa...1684003148.jpg http://forums.pelicanparts.com/uploa...1684003148.jpg I made the rough shape here in some metal i had left over from the seat pan http://forums.pelicanparts.com/uploa...1684003148.jpg blammo Part 2 soon |
Tail Lights Pt 2
http://forums.pelicanparts.com/uploa...1684003148.jpg I used some epoxy here to push the pieces back together as the metal broke over time and whatnot it started to move away and curl http://forums.pelicanparts.com/uploa...1684003148.jpg I removed a few more bits of metal and it worked out great I sanded and cleaned up a lot of the metal - and coated the caps in epoxy; this was the first time attempting this so i wanted to use this as a testing area as they needed to be protected a bit more, and i can learn for future stuff. no real reason to go this wild as its never seen i suppose. http://forums.pelicanparts.com/uploa...1684014542.jpg i now know doing this, that this was waaay too much - just need enough to fill the gaps vs building up material. http://forums.pelicanparts.com/uploa...1684014542.jpg using sanding blocks i did my best to even this out despite going waaaaay too hard on the X part - that was rather tricky to get. I had to stop myself from trying to make it perfect http://forums.pelicanparts.com/uploa...1684014542.jpg was pretty happy with how smooth these now look - like i sad tho its real hard keeping myself from sanding these to get them exactly right. http://forums.pelicanparts.com/uploa...1684014542.jpg The tail light housings were real pitted on the tops - so taking what i just learned from the caps i applied the same method here... still trying to hold back http://forums.pelicanparts.com/uploa...1684014542.jpg these came out real nice http://forums.pelicanparts.com/uploa...1684014542.jpg These painted up real nice as well. I used Dupli-Color Premium Acrylic Enamel white and Rust-oleum bright coat metallic finish ( the metallic paint worked ok, but sprayed a lot of oil that kept me from having a good coat, perhaps more shaking on my part) http://forums.pelicanparts.com/uploa...1684014542.jpg I wanted to replace these weatherstrips - but was unable to figure out where to find em, im assuming its just maybe butyl harded over time maybe? I just replaced them with generic weatherstripping I got from amazon per "afternoon garage" on youtube's recommendation - and this was nice keeping it real clean and simple http://forums.pelicanparts.com/uploa...1684014542.jpg Pt3 coming soon |
I like how you tackle your project.
some advise though, as you obviously still have to do quite some welding (that A-pillar base will reveal its horror once cut open) I would not proceed adding more sound deadening to avoid fire! |
i have night sweats thinking about these portions of the body - for now i painted them to slow it down a bit, but once i can get this driving i can get this taken care of
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