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tt92103

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Discussion starter · #1 ·
I got in my car a couple days ago and the roof fabric had all come unglued and was sagging badly. I had no clue or advanced notice this was about to happen!
I've read some old forum posts. I am trying to take the headliner out, get the old disintegrating foam off of it, and take it to an auto upholsterer to re-glue the fabric on.
I have removed the rear upper trim panel, the dome light assembly, and the visors, and pulled out the fabric. Already broke 1 visor clip and a couple of other plastic parts. I don't know how to remove the side trim panels... do I just pull down hard? I feel certain they are going to break into pieces.
 

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Discussion starter · #2 ·
So far total fail. I don't know what this trim piece is called but it had 4 securing clips and I broke all of them.
I will try to repair them with JB Weld Plastic Bonder...
 

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You need to use long plastic pry bars, preferably where the tip is split like a 'Y' and bent for a pry angle so it applies pressure to either side of the clip. Saw a long metal one that looked like a BBQ fork... wish I had that one. Those 'A' pillars are particularly nasty. The clips at the front bottom are close together and the panel is wedged in the crack between the metal pillar and the dashboard so it needs to pivot to the center of the windshield to be extracted.

The piece you removed is the overhead 'B' pillar trim panel.

I'd start at the rear, and work one clip at a time to the front. Pull down the 'C' pillar at the 'B' pillar join (back of the door) enough to be able to get at the end of the 'A' pillar. Use a prybar or fingers at both sides of the clips or you'll crack the 'C' pillar where it narrows, where the other clips are. Then work the 'A' pillar trim (above the door) to the front. Use something for a prybar that is long and w/o sharp edges to avoid pressure points - that will crack the face of the plastic. I pulled mine off by hand, but broke a couple of clips. There's some good photos in the newsgroups.

What actually happens is the metal clips get stiff and don't flex as easily any more. Which strains the plastic retainers which have become more brittle.

If yours is a south California car, the plastic panels have been 'baking' in the sun/heat for ~20 years, so the ABS plastic will be brittle. Take time and lots of patience - walk away for a while if you have to. When using JB Weld, apply liberally for a thicker wider bonding surface. I used a similar two-stage product from 'Permatex' and applied to the underside of the cracked plastic panel. Never bothered to repair the clips - the clip mounts shattered and I only broke a couple. Worked great - but I was also gentle with putting it back in. The repair on the overhead 'B' panel was perfect as this is where I started and was finding out how the clips worked (DUH!!).

BTW - You can still buy replacement metal clips if you lost any. Saw them on EBay and someone here posted a part number.

I had previous damage to repair as well when the installers for the previous owners dropped the headliner
to install a Nav system and a TV tuner w/ screen. Had 8 antenna wires installed between the headliner and roof. I removed the lot when redoing the headliner. Look up my headliner tread.
 
Discussion starter · #4 ·
Thanks for the advice. I did not continue after botching that trim piece. I will look for the tool you described.
I have the metal clips, the problem is I have destroyed the plastic parts they mount in. Two of the four I was able to repair with JB Weld. On the two others ALL of the plastic is gone and I am going to have to rebuild it somehow. The pictures below show the two that I'm going to have to reconstruct the plastic to hold in the clips. [smiley=bigcry.gif] [smiley=bigcry.gif] [smiley=bigcry.gif]
 

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I had good results fixing a cracked engine compartment cover with JB Weld Plastic Bonder (not sure what flavor of JB Weld you used) and some fiberglass cloth to provide material where I had none but needed something in common for the pieces to attach to. Here's my post with a couple pics which hopefully show what I mean. I think you could use some cloth and JB Weld to reform your base and hold it all together:

https://www.ttforum.co.uk/forum/viewtop ... 7#p9199027

And if you didn't use the JB Weld Plastic Bonder specifically, I'd be tempted to pick some up. The stuff really does seem to stick to plastics that don't like to stick, and I've got to think that JB is doing more than printing up different card stock for their different formulas. :wink:
 
Discussion starter · #6 ·
Reviving an old thread, its been 4 months and I finally got my headliner back in. I bought dark blue headliner fabric on Amazon and had the headliner re-upholstered for $130. I painstakingly epoxied the pillar trim clips back together and fixed the pillars that I cracked using JB Weld Plastic Bonder. To get the C pillar back in (or is it called the B pillar?) I have to remove this black side trim part which is circled... I don't know how to get it out. Is the black part a separate piece or is it attached to the blue piece below it?? Does it have the same type of clips as the pillar trim which will shatter when I remove them?

Obviously I see now that I should have removed this to get the C pillar out back in July, and as a result, there are broken plastic bits behind it from when I tore out the C pillar.
 

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Discussion starter · #7 ·
I used some pieces of Delrin to reinforce and epoxied on with JB Weld. Looks ugly from the back side but good as new from the front side. Top picture is yellow JB Weld PlasticWeld, bottom picture is the black JB Weld Plastic Bonder. Not really sure what the difference is so I tried both.
 

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Discussion starter · #9 ·
Took me two days but I figured it out. The whole panel just pulls straight out, there are 5 clips that hold it in and by some kind of miracle I pulled it off and broke none of the clips! Maybe I'm getting better at it and using the right technique.
This panel must be removed before trim pillars can come off. Found a lot of broken plastic behind it it from the B/C pillar which I epoxied back together last night.
 

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Yeah... the clips are easy to glue back on the side panels as they rip off the panel backing.

If I can suggest, go to EBay and buy an electronic ETKA manual on DVDs. It contains all the factory repair info on VW Group cars. It's what I used for the interior tear down instructions. As a bonus, you get info on all the other VW/Audi cars you'll never own... LoL. Well worth the info for ~$65 or cheaper. Poke around.
 
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