[928uk] Plastic roof tray without sunroof - s2/ MY84

[Ben Hodges]

Glue and foam underneath the vinyl?

Yeah mine was pretty wrecked too.

Rough steps I followed below:

1) Removed the old under vinyl foam with a brass wire fitting on a drill.

2) Straightened the (rubbish) fibreboard material using acetone to soften
first and then a multitude of different clamping methods. Had to introduce
some aluminium sheet strips epoxied on to help keep it straight (applied to
the side facing upward).

3) Repaired damaged areas with old school Poundland super glue which soaks
into the fibreboard and helps bond it back together (watch out for fumes).

4) Repaired / reshaped larger areas with fibreglass including the clip
mounting areas.
You can also do quick repairs using the fibre material + superglue for the
smaller areas.

5) test fitted liner and adjusted clip positions using the quick repair
method mentioned above.

6) Once happy with fitment - covered board with 3mm closed cell foam. Use
the brush on high temp glue and not the spray adhesive (even the 3M) is
shite for this job. Had to redo the whole lot because of (expensive) glue
failure.
You have to take care in getting the foam to adhere to all the little
curves, recesses etc otherwise it’ll look rubbish. If it doesn’t look
perfect remove foam and start again.

7) Finally cover with vinyl sourced to match your cars interior as closely
as possible. Plenty of options on eBay etc. Obviously it’s not going to be
factory matching but I found a good match and no one will notice unless
you’re going to a concours event!
As per applying the foam care is needed to get the vinyl on with no lifting
in recessing etc. Any minor bubbles can be taken care of using a needle and
then applying pressure. The glue curing can also cause and require this.

8) Use an electric stapler with 4mm staples to secure the vinyl to the
backside of the board.

It’s not an easy job but doable if you’re reasonably handy!

Cheers
Ben

On Tue, 18 Jun 2024 at 19:51, 21Gmail <mike.weightman21 at gmail.com> wrote:

> Hi Ben
>
> Yes, got the original but it’s suffered whilst removing the glue in order
> to apply new headliner… plan A is to try to repair it with resin.
>
> Cheers
> Mike
>
> Sent from my iPhone
>
> On 18 Jun 2024, at 19:36, Ben Hodges <benhodges1975 at gmail.com> wrote:
>
> 
> Hard to find in good condition Mike as I’m sure you’ve already worked out!
>
> I ended up straightening and recovering mine.
>
> Do you still have your original?
>
> On Tue, 18 Jun 2024 at 16:36, 21Gmail via 928uk <928uk at lists.928.org.uk>
> wrote:
>
>> Dear 928ers,
>>
>> Does anyone know where I could source a replacement plastic roof tray /
>> liner without the hole for the sunroof - s2/ MY84?
>>
>> Thanks
>> Mike
>>
>> Sent from my iPhone
>
>