First timer headliner and rear window install.....

[Tbone425]

Of the course of the last two days I've put in a new headliner and installed the rear window. Thought me experience might encourage others to take this on themselves. First, I should point out that I am building up from a bare shell so the issues with removal did not apply. The headliner was very straightforward and the only thing I would say would be to buy LOTS of binder clips. The small and micro (Staples) were both used. Mostly the micro because they are almost the perfect size to fit the lips around the car. Being smaller they are not as aggressive an angle at the contact surface. Being as my car is a sunroof model, a started by centering the back portion (top of back window) to align the zipper. I then moved to the front and placed one dead-center at the top of the windscreen frame. That created a triangle that was square to the roof.from there I worked side to side until it was completely tensioned and clipped up. After that it was just a matter of gluing small sections. Not hard, just time intensive because you have the wait for the coats to dry. I did the top of the rear window first. Then each rear pillar. After that I moved to the front and did the center 1/3, then the door top sills. I left all of the pillars for last, and gave myself about 5" in each direction to work with for fitting. This was an easy (without windows in) project that provided lots of gratification.

Next came the rear window. I started with a old seal (cut off the glass), the new seal and a cleaned window. While is didn't take a meter to it, I checked the condition of the grid for scratches and voids. With everything laid out on my wife's dinning room rabble, a took note of the orientation between the old seal, new and the window. I made a quick sketch of how everything was coming apart and snapped a couple pictures as well. Then, as I extracted the wires I laid them on the glass at the locations they would be reconnected. Only trouble I ran into was the channeling of the wires, it just takes time and a little patience. After making small razor cuts and channeling the wires from their own channel to the glass mounting channel it was on to the mounting of the glass in the seal. This was easy as can be. However, the trim was a bear to get in correct had to start over a few times. Being bent a number times, mine had started to change on more than 1 axis. Oddly enough, the easiest part was the actual install. What I used was a length of 1/4 inch heavy gauge natural fiber cord. It sat in there great. I had the two ends crossed over each other at the bottom center of the window. My rational for this that the larger diameter creates a longer "moment" while the seal is open to accept marriage to the chassis. But not so large that it would bind the entire opening. Having stayed up half the night getting the headliner in, the idea of having a bunch of dish soap, or other lubricants all over my work was a no-go. And I thought this method would be the best option for a dry fit. The natural fiber cord is important because it was the perfect texture to slide over the headliner material but the fiborouseness of the cord bit into the rubber enough to really pull it. The sill was freshly painted but a good solid clean and wax might have the same effect. Since I was working alone, I started on one side pulling the cord all the way around the corner then back to the other side and did the same thing... Back and forth just past the top corners. Then straight across. While I was pulling I was also applying about 10-15lbs pressure on the outside of the glass. I was able to do this because my popout windows had not been installed yet. First try, dry, alone and it was in snug as a bug and no damage or pull-away on the headliner. If the sill were rough I might have dragged a finger line of soap around the seal to ensure a smooth seating. So.....before this I had never installed a headliner or a window in my life. Hope this might help another guy out there looking to tackle this. If anyone would like I can post photos as reference. I would certainly do a front window as well but mine was broken and install is "included".

[Tbone425]

Ps, If anybody in Seattle (or willing to pay a few bucks shipping) wants a few hundred lightly used binder clips for their headliner let me know. I paid about $35 for them. As this was the first time I had one in my hands in about a decade, I don't see myself needing them anytime soon....

[pdtweeks]

kudos on tackling the headliner Tb.....one of the more intimidating tasks on any car, especially a 911. I just completed the headliner on an '83 SC and have quite a few of those clips left over as well !
Next up, covering those A & B pillars.

[jittsl]

My guess is that you used OEM seal on your rear window. Whenever I have had an issue it was because I was trying to save a few bucks on the rubber.

[Tbone425]

The only complaint I had was the URO seal I used. Having to do it again, I would use OEM. It took some real work in the corners and still has a couple small creases at the inside radius. I might take it out and go OEM. After all the work, it hard to notice the creases but, like many of you probobly, it will drive me nuts over time. It will be the only thing I see when I look at the back window. I'll let you know when I change it out.....and if I can make lightening strike twice. I really do think that the rope was the cornerstone to getting it done. The other thing I would have done was run the wires back down into the chassis before setting the window. I just fished a piece of wire up from the motor bay and pulled them back through...not difficult but unnecessary if planned better. Also, I ran the grip of a well used pair of pliers in front of the rope to set it. Slid through like butter. A tackier, newer handle would not slide clean, it wanted to bind.

[Tbone425]

A couple of throw pillows from your family room couch also make a nice dolly that spins easily on your dining room table and elevates the entire edge......but does run you a chance of conflict with other non Porsche-project fans in your home. You've been warned.

[tirwin]

Great job!

I did the same thing a couple of years ago. Now I have a lifetime supply of clips to keep my potato chips fresh.

[$ Short]

Thanks for the post. This is in the near future.

[Tbone425]

In a related story, I had a pro put the front window in....not fun. It took three of us ( me helping the two guys). It could be done by a diy type of guy but in my case it was a new windshield. If it's going to get broken I'll have someone who will foot the bill do it. The front trim wash a real PITA. Headliner stayed put though!

[irl]

Because this was a shell, what did you do for the A and B pillar material

[joefrantz]

Congratulaions from yet another member of the excess binder clip club. You've just made short work of two on the nastiest jobs in 911dom.