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A couple months ago, I posted a list of a few projects I wanted to tackle in Lance, our Winnebago Travato.  One of them was to insulate the area over the headliner in the cab area. But I’d been dreading it, because it seemed like a lot of work and bloody knuckles.

But since I’m stuck home and nobody is traveling, I finally ran out of excuses for not getting started, so here we go.  This video was the easier part of the project, because I just got to take things apart.  Taking things apart is easy.  Putting them back together less so…


The video is a little rough, because I hadn’t done this before, and didn’t really know what to expect when I started.  It turned out to not be as bad as I had imagined it.  In fact, if I were working with an empty cargo van (instead of a fully built-out RV), I could probably remove the headliner in well under an hour now.  The ProMaster parts weren’t that bad.  You’ll see what I mean in the video.  One thing to point out is that yes: you do need to remove the lower headliner and shelf before you can remove the upper headliner.

I won’t run through the entire process here, because it’s in the video, but I will highlight a couple of tools that I found indispensable.

Panel Clip Removal Pliers

Don’t even bother without getting these.

Oh my goodness I couldn’t have done this without this extremely specialized tool!  Fortunately, I had anticipated the need for these and had purchased them off of Amazon ahead of time.  I suppose it might have been possible to remove all the panel clips (there were maybe 13 of them) with screwdrivers and pry-bars… but I would have destroyed a lot more of them.  As these came out, I think I will be able to re-use all of them but one.  This thing was only about 15 bucks, and worth every penny.

Magnetic Parts Tray

Now taking bets on how many of these I have leftover next week.

As you’ll see in multiple places throughout the video, I have a hard time keeping track of screws and other items that I remove from the van.  Usually, they fly every which way and I’m lucky to capture 75% of them.  My problem would be a LOT worse if it weren’t for this tray.  I’ve had this thing for a while now – another Amazon find.  I’ve used it for many projects, but on this one I was really feeling the love.  Not all of the parts on this project were magnetic, but the tray gets to be pretty jammed up with screws and such, so that even the non-magnetic parts stay snagged in place.

What’s Next?

There are three things left to do here.

  1.  Add FatMat sound deadening mat to the headliner to make things even more quiet.  Why FatMat?  Because I had some left over!
  2. Add Rockwool insulation to voids and to the headliner area.
  3. Reassemble…

It’s number three that I’m worried about, so we’ll see how that goes this coming weekend.  Wish me luck!!