The fabric came from JoAnne's; they have quite a selection of headliner fabric. I chose 3M Super Yellow Trim adhesive after reading many articles on the different adhesives that could be used.
The headliner itself was a breeze to remove. Remove the sun visors and retainers, the dome light, door trim and three plastic rivets and it's out. The next part was time consuming but not difficult: removing the degrading headliner and foam from the backer board.
After peeling off as much as I could by hand, the trick to getting the rest of the foam and gunk off the backer board was to use a plastic putty knife followed by a wire brush to scrape away then brush off the old foam.
Once done I had a nice and clean substrate on which to glue the new fabric. I started by sizing up the fabric and folding it over on itself. This would allow me to work on half of the headliner at a time. I used plastic to protect the "show side" from adhesive overspray.
Following the adhesive directions, I sprayed both the backer board and the fabric back with two passes of the adhesive. After setting for 5 minutes, I carefully started from the middle and worked my hand from the center towards the side, pressing the fabric down as I go. I worked slowly and made sure that the fabric did not touch the contours of the backer until I was ready for it to do so. There were no surprises here and once the first half of the job was done I repeated on the second half.
I let the adhesive dry overnight before using a razor to trim the sides and cut out the mounting holes. As the last step, I flipped the headliner and glued the edges of the fabric onto the backside of the backer to ensure that anywhere the edges might be exposed had a finished look.
After about an hour, I reinstalled the headliner back into the truck. I am very happy with the way this job turned out. To me, this looks just as good as the factory installed headliner. Only time will tell if the adhesive holds-up in the Tennessee summers...
