We all know what a pain it can be to take out the headliner board in order to redo the headliner. Especially for cars with sunroof. When I removed the board from my 86 parts car, it crumbled into many pieces.
My solution:
Bondo Fiberglass Repair Gel, a mat of fiberglass large enough to cover the entire board and a big tolerance for a lingering smell.
Lay the board on a flat surface, with the upside up (not the side you apply the liner to), mix the gel with the red catalyst and apply an even surface on the board.
Press the fiberglass mat down on the board into the gel nice and even, working out any folds or ripples.
Then apply another layer of Bondo onto the fiberglass mat and work it into the fiber.
After about 45 minutes my headliner board was nice and stiff again, which makes it much easier to reinstall.
I cut the excess mat off with boxcutters and am now waiting on my liner fabric, for which I will use 3M Ultra Spray adhesive. I've used it before and it works well.
Garage smelled bad for about 2 days.
Total cost without liner fabric: $18:00
\D
