Suggested time: 12-20 hours
Level: Intermediate
Prerequisite: Modules 2, 3, and 5
Foundational Objectives
Common Essential Learnings Foundational Objectives
| Learning Objective | Notes | |
| Door Panel | ||
| 24.1 | To inspect the door panels. (CCT) | Examine the door panel to be recovered. Determine the best way to remove the panel from the door. A service manual for the vehicle can be helpful. |
| 24.2 | To remove or repair the panel. (IL) | A thin tool may be required to depress the holding tabs or buttons behind a panel. Remove the hardware and arm rest from the panel. Repair or replace the door panel if necessary. |
| 24.3 | To measure and lay out the fabric. (NUM) | Measure and lay out the fabric to be cut. Do not remove the previous fabric. Make sure that the replacement fabric is at least 125mm (5 inches) larger than the door panel. Mark the location for each piece of hardware. |
| 24.5 | To reinstall the door panel. | Align the tabs or buttons and reinstall. The hardware will hold the door panel tightly to the door. |
| 24.6 | To calculate the cost of materials. (NUM) | Have students itemize the cost of materials and prepare a bill. |
| Headliner | ||
| 24.7 | To inspect headliner in a vehicle closely. (CCT) | A general rule is that the older the vehicle, the harder it is to replace the headliner. A shop manual will show where any hidden fasteners are located and explain how to remove and replace the headliner. New vehicles have moulded, snap-in kits. It may be possible to purchase one from an auto supplier. Be aware some vehicles need to have the windshield or rear window removed to install headliners. Inspect and choose carefully. |
| 24.8 | To remove headliner trim. (TL) | Carefully remove molding and trim. Create a journal entry describing how the mouldings and trim were disassembled. Use a sketch or photograph as a reference. Remove rearview mirror, sun visors, dome light, and garment hooks if necessary. Disconnect the battery to reduce drain to dome light and other accessories. Mark the location of any screw holes to be put into the headliner with masking tape at the location on the outside of the vehicle. |
| 24.9 | To remove the headliner. | Some headliners are glued to the roof. Cautious removal of the headliner will preserve the pattern for later use. If bows are used, some are snap-on and some are screw-on. Some roofs have multiple bow holes, so it is important to mark or record the holes from which the bow originated. Clean the bows if dirty or rusty to prevent staining the new headliner. |
| 24.10 | To inspect, replace, and reglue the insulation. (CCT) | Insulation may sag over time. If sagging insulation is in good condition it may be reglued. If it is rusted or stained, replace the insulation. |
| 24.11 | To install the headliner. | Work from the rear to the front when installing a headliner. Mark the back of the headliner with a chalk centreline to help while fitting it. Trial fit the headliner and ensure all bows are in the proper position. Some automotive trim adhesives are multi-temperature contact type adhesives. Glue the back centre and then work outwards to the corners, pulling tightly to remove wrinkles. |
| 24.12 | To remove minor wrinkles. (IL) | Most minor wrinkles can be removed with steam. Use a water spray bottle in one hand and a hair dryer in the other hand. Move slowly, using as little moisture as possible, as too much water or heat can do permanent damage. Do a practice project before attempting full job. |
| 24.13 | To reinstall accessory items. (TL) | Reinstall mirrors, visors, domelight, and garment hooks. Use a scratch awl to puncture headliner for screw holes. |
| Project: Build a small box and attach some headliner material with wrinkles. Use the hair dryer and water spray bottle to practise removing wrinkles. | ||
| Carpet | ||
| 24.14 | To remove interior components. (COM) | A factory manual will explain procedures for removal of console, seats, belts, and door sill plates. Seat belts often use torx screws. |
| 24.15 | To remove carpet. (CCT) | When removing carpet, it is important to check for water damage, rust or other minor damage. Repair any damage found before replacing the carpet. Clean the floor down to the base metal. An electric drill with a wire brush attachment will work well. Rust and grease must be removed prior to painting the bare metal. A metal prep must be used before paint is applied. |
| 24.16 | To cut padding for carpet. (IL) | If using aluminized insulation, a kraft paper pattern is useful. Duct tape will seal the edges. Some insulation kits include adhesives. |
| 24.17 | To install padding for carpet. | Numerous styles of padding are available. Select the type best for the job: jute padding, layers, closed cell foam, or rubberized foam. |
| 24.18 | To secure carpet and padding. (IL, TL) | Gluing carpet in place is best; however, carpet may be left loose if access to anything under the carpet is necessary. Use of double-sided tape instead of adhesive will allow access beneath carpet. Trial fit the carpet prior to final installation. Mark holes with chalk and cut "x" in the material with a razor knife. Make holes as small as possible. Cut a bolt hole and place the bolt, so carpet will not slip or move. Use caution so that the carpet does not unravel when drilled. |
| To trim excess carpet. | 24.19 | Many carpet installers trim the excess carpet only after the seats, console, and belts have been reinstalled and marked. |