Headliner Shell Fit Check

Finished removing and cleaning the fiberglass headliner shell, and I learned a lot of how to, and how not to do things. The mold was destroyed in the process, but since this is the only part in existence, there is no need for another mold.

I'm quite surprised at how well it fits in place. Maneuvering the big flexible shell in through the window opening by myself was a pain, but I made it!. As expected, all the sides need trimming, but that was the intent. Better too big, than too small. Only one corner came up a fraction short, and it might work, but I can't measure that accurately until the re-chromed windshield surrounds are returned. I might have to add a small patch if the chrome piece doesn't quite cover it.

The other area that could be a problem is where the visors mount, but that will also have to wait for parts to verify.

After trimming, I will add a final coat of resin to the fabric surface to repair a few places gouged when the mold release didn't do its job, and I will also reinforce the back side if needed. If I decide to use chrome strips to keep it from sagging, it won't need more reinforcing. That decision will depend on if I can find the plastic trim/windlace that secures the headliner to the roof rails.

Funny How Time Slips Away

As I was looking back at old blog posts, I was amazed that car related things that I thought happened just a few weeks ago, actually took place a couple of years ago! Between trying to sell two houses half-way across the state, having out-of-state visitors, trying to finish all the projects on my wife's to-do list, and being slowed with health issues, I haven't accomplished much in the way of car reconstruction recently.

I did finish laying fiberglass, but have yet to separate the shell from the mold. Because it's thinner than the typical molded part, I have to be very careful not to crack it during removal. I now wish I had used a thin plastic wrap, as a mold release. The paste wax didn't do the best job as a mold release, even after five coats. I have it loose around the edges, but I might have to destroy the mold to convince the middle portion to release.

Wiring behind the dash is going to be a nightmare with all the A/C hoses and the Vintage Air housing eating up the already limited space designed for the stock heater. I decided to cut off the lower portion of an old, rusty Savoy dash that came with the Belvedere, and use it to more accurately locate duct outlets and wire bundles. At least I'll be able to access most of the work from the front, instead of having to lie on my back and work overhead.

While working on the end of the console where it meets the dash and firewall, I decided it would be a good idea to re-design the home made metal duct intended to direct air toward the driver's floor. There just wasn't enough clearance to jam everything that has to fit in that tight area. I finished the new duct, and incorporated a mounting bracket for the A/C relays, so I hope I pick up enough room to stuff everything out of sight and in a way that the wire bundles don't rub.

Fiberglass at Last

The great experiment to create a headliner that uses modern fabric glued to a headliner shell is underway. Though the weather turned to cool days and cold nights, I had one day of temps over 70 so I could build the first mat layer. There were a few problems, but nothing unexpected or too serious.

I hope to keep the weight down by adding and additional layer of glass only in the areas where it will be attached to the body. Temperatures to work with the resin won't be high enough until late next week, so I have to wait again. I could heat the workshop, but the odor is more than I want to put up with in a closed area.

I took a drive to the plating shop I used for my last batch of parts, and discovered they no longer chrome plate due to new EPA regulations. There is now only one place left in Fort Worth that does chroming. I found a place in a smaller town near the Oklahoma border that does show-car chrome at show-car prices, and since they modified their shop to comply with government regulations, the price estimate was about three to four times the price a similar amount of work cost two years ago in Fort Worth. It's easy to understand why new car trim is all plastic.

No word from the machine shop doing my steering column work, other than they are falling farther and farther behind since the owner had his heart attack. It's been three months, and they have their regular customers to pacify, and are not too concerned about a customer who brings in a small job now and then. I might have to search for another machinist, but that shop has the best reputation and I hesitate to take a chance with the other local ones. I'm glad I don't have a real need for it yet. Maybe it will arrive in Santa's sleigh!