For new roof-lining I am using a heavy weight curtain lining material and 2cm thick wadding to give a plush feel
The first step to creating the new roof-lining consisted of draping the new lining over the metal frame and then
trimming to a size slightly larger than the frame. As can be seen from the right hand photo above I have got
three layers of material:-
These three layers were laid over the metal frame and pinned along the contours of the retaining bars.
As the photo above is for the rear lining section, the lines are curved to follow the contours of the frame and not
the results of a drunken sowing machine incident!
Once the three layers have been pinned together it can all be sown together using a sowing machine.
Before attaching the fabric to the frame the fabric should be ironed. Caution should be taken when ironing, don't have the
iron to hot as you don't want to damage the wadding.
The fabric can now be pulled taught over the frame and hand sown in place. I used double sided sticky carpet tape to
hold the fabric to the edges of the frame.
Rear section with new fabric and a zoom showing the fabric pulled over the frame and sewn.
Note that the hole for the rear window will be cut out when the frame and fabric is in-situ.
Click here for an image of the complete frame with new fabric ready for refitting into the car.
Soundproofing before re-fitting the frame and fabric.
As the old soundproofing was rotten it was discarded, this will have to be replaced before refitting the frame and fabric
I have used a 2.5mm thick, high density synthetic soundproofing membrane from Custom Audio
I have used part SY50, a self-adhesive material weighing 5KG/m2. This is the same material that I am using to soundproof the
floor and front bulkhead of the car. The primary function is to remove any vibrations in the roof. This will not require a solid
mat of soundproofing and small strips will be sufficient.
Strips of soundproofing applied to the roof.
(Note: the white marks are the glue that previously held up the original OEM soundproofing material
In a very non-scientific demonstration of the effectiveness of the sound-proofing I have recorded two sound files of a small
10mm washer being dropped onto the roof from a height of 20cm
This sound is before the sound proofing.
This sound is after the sound proofing.
The waveform below show's the effectiveness of the soundproofing a bit better.
The white waveform has a higher amplitude and lasts for 1 second. The inset blue waveform has <%50 amplitude when compared with
the original and lasts for only 0.37 seconds.