Got some time to fabricate a new headliner for the top.....
1/8" Baltic Birch was used for the new headliner base plywood. Since BB comes in 5'x5' sheets, this allowed elimination of one of the joints in the headliner since I would only need 2 pieces (SMB uses 4' x 8' sheets of plywood requiring 3 pieces). The total length of the headliner is 48+48+21.5=117.5" x 53" wide.
Using the old headliner pieces as a template, holes were drilled in the new ply for the J hooks, padded support thingies, lights, etc. and the end corners were radiused. The new pieces were cut about 1/16" undersized all the way around to allow room for the folded-over padded headliner.
Before gluing on the material, the wood was test-fit to the top to confirm that everything lined up and that I had space for the material wrapped around the edges.
The headliner material was purchased online at http://www.yourautotrim.com
. These guys have lots of choices, from regular stuff to ultrasuede, perforated vinyl and even camo headliner material. I bought a headliner sample kit before ordering the material to evaluate the color match with the rest of the PH trim. The color is called PH1769 charcoal and it's a close match to the SMB grey velour fabric. I also bought 3 giant spray cans of DAP weldwood high strength contact adhesive from the same place.
Here are a few action shots:
Laying out the prepped plywood on the back (foam side) of the headliner fabric
Spraying the contact adhesive (also applied contact adhesive to the plywood not shown...)
Carefully "rolling" the plywood on the headliner without making any bubbles.....the only real stressful part of the job.
Using a veneer roller to get the pieces stuck together
Applying a 2" strip of contact adhesive to the perimeter of the wood and folding over the material. Note the mitered corners.
The finished product! (repeat steps above for second piece...)
I still need to poke holes in the fabric at various places and will attempt this with a leather punch.