I have a 1986 Volvo. I need to know where I can purchase a new headliner to put in my car. I need the part to the sunroof as well. I also need to know if anyone knows where I can purchase a new seal for my sunroof. When it rains or I wash my car the water gets into it and it ruins the headliner. If anyone has any information could you please let me know I wouold really appreciate it. I also would like to know if anyone knows why my sunroof is hard to open and close. It is hard to get closed and then it does not seal right and the water leaks in. If you know anything about this please let me know.

lotsa questions... answers in parts:

1) Headliner material or backing board? The former can be purchased at any fabric store for about $50-$80... just measure what you need and ask for 1/8" thick headliner in the appropriate color. If they don't have 1/8" have them order it, don't buy 1/4" instead under any circumstances (it's too thick for certain applications such as the edges near the sunroof opening). In the case of the latter I suggest you try to use your existing backing board by fixing it if need be. Your next best bet is a junkyard, where you may find a complete or better one. Your last option (not really an option) is volvo, who will charge you something like $800 or smore for a new one (I heard over $1000, but I still find this hard to believe).

2) The seal shouldn't matter for the water... it isn't water tight to begin with, and water that leaks in should drain out the hoses in the four corners. If you are getting bad leaks you may want to check the drain hoses to see if they are blocked up.

If it's still really bad you can get a replacement at a junk yard or buy a new one from volvo (I don't know how much Volvo charges since I just found my replacement in a junkyard off an early 90s 700). On a sidenote, use silicon or caulk in the groove to affix it to the sunroof panel, and fill the inevitable crack between the two ends with caulk or silicon as well.

3) If the sunroof doesn't sit right take a look at the 700/900 faq section. There are a myriad number of possible causes, from loose adjustment screws to broken support struts. On a side note, your car is an early design and invariably has the flawed sunroof support brackets and venting design (mine is an 85 and had the same problem... theres a big post about it in the FAQ). In short, this design flaw leads involves the breaking of the support struts and leads to an inability to stablize the sunroof's sitting position regardless of whether the adjustment screws are tight or not.

good luck,
rt

I wonder if anyone has made their own backer board from the Volvo pattern out of their car. What material would work? Would this be a big job? (I confess I've never replaced a headliner.)

Good question. Hell, if you could do it in any quantity you could sell it on the board for $300+ and make some funds (to be redirected into said brick ;)

However, unless you have some know how and gear it would be hell for a couple of reasons:

1) The material used has to be both light (to avoid coming down under its own weight) and sturdy (due to the fact that there are expanses only tentatively held in place by the pieces own structural strength).

2) The piece is molded to specific dimensions, and the curved section (thinking wagon here) that leads to the back might be particularly annoying to duplicate.

I guess the real question is this: without a machined press to mold the stuff what would you material would you use to make it? A thin sheet of aluminum might be PERFECT, but it would be damned expensive unless you are a metalworker with experience and tools... actually any metal might be dangerous in an accident since the roof could turn into some type of horrible guillotine (I'm thinking of that scene in The Omen where the plate glass slides off the truck...).

Have to think about this... sounds like an interesting project. Thanks for the idea, I've been running out of ways to procrastinate lately. ;)

-rt

Idea: if the old one came out in any decent shape (even though cracked) one could reassemble it as a mold, cover it with mold release agent, and build a new board out of fibreglass cloth laid on top.

that's not a bad idea, not bad at all. as long as you were gentle with the board you could probably do it pretty easily. you could probably make a new mold out of something stronger like metal, but that might be an unnecessary and costly step.

do you know how adhesive reacts to and holds on to fiberglass? The only fiberglass work I've done was on a boat, and I use bolts and seals with caulk or silicon on that (since I doubt any adhesive or stickum would ever hold up to the Atlantic). wondering if the adhesive would hold up over time and keep the roof on headliner on the board.

-rt

You can get the sunroof kit from www.ipdusa.com and the seal from www.borton.com. See the FAQ for more information about how to do this.

I bought my headliner kit from IPD, I suggest you call them and get their free instruction sheet before you buy it. It is an awfull lot of work, especially the sun roof which has to be removed. I have found auto upholstry shops around me that will do it for $ 350. I believe the IPD kit cost me $ 139

you could buy all the materials IPD supplies (sans instrucions) from a fabric store for under $80.

you don't have to have the fabric store do it, they just have aq lot of experience doing it and will make sure it looks perfect.

I personally did my own on a saturday with materials I bought from a fabric store (industrial spray adhesive and headliner material).

-rt