DIY Network

Carbon-Fiber Interior: Headliner Installation From "Tricked Out" episode DTRK-201

	The project car: a 1997 Civic hatchback.
	The carbon-fiber headliner replacement we added to this vehicle is black. We left the factory plastic pieces their original light grey to provide contrast. As an option, you could sand and paint the plastic parts to match the headliner.

NOTE: Images on this page may be enlarged for enhanced viewing simply by clicking on them.

In this episode of Tricked Out, the interior of a 1997 Honda Civic is dressed up with the coolest in carbon-fiber accessories. In this second segment, host Andrew Totolos removes the stock headliner from the car by taking apart much of the plastic that attaches to the headliner area in the front, sides and rear of the car. The new carbon fiber headliner goes in and all of the components that were removed to get the old headliner out are re-inserted.

Materials used in this episode:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this episode include:

Dash overlay kit
Headliner
Cargo cover
Shift knob
Emergency-brake handle
Panel-removal tool
Grease and wax remover
Fine-grain sandpaper (optional)
Spray paint made for fabric and vinyl (optional)
Fasteners
Adhesive promoter
Masking tape
Rubbing alcohol
Paper towels
Hacksaw or rotary tool
Cordless drill and screwdriver attachment

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

DIY Difficulty Rating for This Project: We gave this a difficulty rating of 3 on a 5-point intermediate-level scale. Experienced gear-heads should have no problem
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Figure A

Carbon-Fiber Headliner: Installation

• So far all of the trim panels that surround the headliner at the top have been removed. After removing the panels, the safety grab handle, coat hanger and sun visors must also be taken out. All of these parts simply attach with screws and are easily removed. To remove dome light, pop off the cover, remove screws that attach it to roof (figure A) and unhook the plug.
  

• Note: We opted to keep the original light grey color of the original plastic parts which would provide contrast to the dark carbon-fiber headliner and blend with the overall silver look of the car. If you want the plastic pieces you've removed from the car (figure B) to match the new carbon fiber headliner you can paint the pieces. Sand down the pieces with fine-grain sandpaper and use a spray paint that's made especially for plastic and vinyl (figure C). You can also purchase dye to color-match the fabric of the sun visors. (Our carbon-fiber headliners didn't have pre-drilled holes for the upper grab-handles, so we discarded those.)

  Figure B

  Figure C

  
  

• The only things holding this headliner in place at this point are the screws in the rearview mirror and the rear hatch weather-strip at the back. Remove those parts. Then, with assistance from a helper, remove the car's factory-installed headliner.

• Once the old headliner is out, putting the new one in is a matter of doing the whole procedure in reverse. The headliner isn't terribly heavy, but it's kind of delicate, so it's a good idea to have a friend there to handle one side while you get the other.

• Start with replacing the mirror screws (figure D) and the trim panel in back (figure E) to hold the panel in place. Once you get the front and back panels secured you can finish up the rest by yourself.

  Figure D

  Figure E

  
  

  	Figure F
  	Figure G

• Begin installing original plastic parts. Start at the front with the visors (figure F) and work your way back.

• Important: Carbon fiber is strong but brittle. Be careful not to over-tighten the screws and crack the composite as you replace all the headliner-mounted accessories.

• Tricked Out Tip: Auto parts stores often carry interior fasteners in a variety of colors. When an interior modification results in a change in color scheme, you may want to pick up some colored fasteners to match the new color. For example, for our black carbon-fiber headliner, we used matching black plastic fasteners. Color-matched fasteners make a big difference for a small amount of cash.

• Once headliner is secured it's time to replace the trim panels. Start at the front with the A-pillar trim piece and work your way to the rear of the car (figure G).

• Re-secure the seatbelts. The seatbelt mounting bolt should be torque-tightened to 25 foot-pounds.
  

• Replace all the trim screws as you go and plug in the speakers before securing the rear lower trim (figure H). Repeat the process for the trim pieces on the other side.

• Replace the rear center trim piece (figure I), the weather stripping and the backseats.

  Figure H

  Figure I

  
  

  Figure J

• For our Civic, we also added a carbon-fiber cargo cover which simply snaps in to replace the factory piece (figure J).

Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

Honda & Acura Performance Handbook (Performance Handbooks)
Author: Mike Ancas
Order this title from Amazon.com.
June, 1999
Publisher: Motorbooks International
ISBN: 0760306699

Honda/Acura Engine Performance: How to Modify D, B and H Series Honda/Acura Engines for Street and Drag Racing Performance
Author: Mike Kojima
Order this title from Amazon.com.
April 2002
Publisher: HP Books
ISBN: 155788384X

Honda/Acura Performance Handbook: High Performance Modifications for Street and Drag Racing Applications
by the editors of Sport Compact Car Magazine
Order this title from Amazon.com.
November 1999
Publisher: HP Books
ISBN: 1557883246

Special Resources for Tricked Out episode 201

Vibrant Performance
Website: www.vibrantperformance.com

Topshop Co.
Website: www.topshopheadliners.com

DragonAutomotive.com
Website: www.dragonautomotive.com