The first cut is the neatest

Headliner project gets real

Lots of measuring, drawing and making templates. Now it’s all about to get very real. Time to transfer the refined dimensions over to the flexible ply. Final amends made to my design drawings,

double-checking dimensions before final cutting
double-checking dimensions before final cutting

The moment of truth

It was a good fit last time, but I knew with a couple of final tiny amends, a good fit would become a great fit. It would annoy me if I didn’t make the changes, as they would be easy to do. Now to see if these tiny alterations made the difference I was hoping for…

drivers seat overhead view of the ply headliner
drivers seat overhead view of the ply headliner

Happy with the headliner fit

Much nicer fit, pretty happy with that. It follows the front double curvature of the cab roof nice and snuggly. It starts to give an indication of how it will begin to look when it’s all finished. Exciting times ahead!

front fit details of the ply cab headliner
front fit details of the ply cab headliner

Having the clean/smooth line of the ply headliner temporarily in place, it gave a very different feel to the interior of the camper. Funny how these things can make such a difference to the vibe of a bus.

all about the fit details of the ply cab headliner
all about the fit details of the ply cab headliner

Little details I know, but I’m pleased with how the headliner fits sweetly around the small angular junction of the central overhead air vent. It makes me happy!

Small things, big difference

Now I know the final changes all work as I had hoped for, time to get busy and make the other one now! Back to clearing out stuff in the kitchen and making room to do some woodwork again.

carefully setting out the final dimensions of the headliner
carefully setting out the final dimensions of the headliner

Strange to be back working with flexible ply again. I was getting used to using tape, scissors and Proplex for the work. Still lots of checking and double-checking of all dimensions before breaking out the knife to cut it out. Always better to be safe than sorry.

cutting the flexible ply headliner to finished dimensions
cutting the flexible ply headliner to finished dimensions

Headliner twins

It was handy having the first cab headliner piece I’d made as a reference. I could quickly use it to visually double-check everything before committing to cutting out the new one. It felt good to finally have the pair of ply cab headliner pieces made.

All about the headliner details

Hopefully, these two small pieces were the hardest to get right with their various angles and double curvature shape. Although not in their final finished state, they were pretty much done for the time being. Next up, the two larger sections for the rear cargo area of the bus. Hopefully, these might be a little less complicated!

enjoying the golden hour sunlight
enjoying the golden hour sunlight

Although it was getting a bit ‘golden hour’ late, it was still nice to go for a quick drive in the bus – any excuse old excuse! There was something I wanted to see/do before it got too dark…

 

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